Engine, Mounting on Assembly Stand

Engine, mounting on assembly stand
When working on the engine, it should be secured to the assembly stand support clamp VW313 using the engine and transmission bracket VW540 and supplementary set VW540/1B.

Work sequence
^ Move engine/transmission assembly to a work bench with jack VAG1383A.
^ Lower engine/transmission assembly so that transmission is on work bench.
^ Remove engine/transmission connecting bolts.
^ Pressofftransmission.

Vehicles with automatic transmission
^ Remove nut from torque converter.
^ Remove hoses from ATF cooler.
^ Seal off ATF cooler with clean plugs.
^ Secure torque converter against falling out after separating engine from transmission.

Continuation for all models
^ Attach lifting tackle 2024A as follows and lift off engine/transmission jack VAG1383A with workshop crane.
Pulley end: 3rd hole of lifting rail in position 2
Flywheel end: 3rd hole of lifting rail in position 8

CAUTION: Hooks and locating pins must be secured with locking pins.

Note:
^ Positions marked 1...4 on the bar must face toward belt pulley end.
^ The holes in the hook rails are counted up from the hook.

^ Secure engine to support clamp VW313 using engine and transmission bracket VW540 and supplementary set VW540/1B. Dowel sleeves must be removed.

Engine installation notes

Installation is performed in the reverse sequence, Note the following:

WARNING: When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:
^ Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.

^ Insert new dowel sleeves in cylinder block for centralizing engine and transmission.

^ Fit intermediate plate onto sealing flange and slide onto dowel sleeves (arrows).

Vehicles with manual transmission
^ Lightly grease input shaft splines with G 000 100 grease.
^ Check clutch and clutch operating mechanism, then install.
^ Install gear shift mechanism, adjust gear shift cables if necessary:

Vehicles with automatic transmission
^ Install selector cable on transmission, adjust if necessary.

Note: Always replace selector cable circlip

Vehicles with air conditioning
^ Install air conditioning compressor.

Continuation for all models
^ When installing engine/transmission assembly, ensure sufficient clearance to engine and transmission mountings and radiator.
^ When doing this guide power steering pressure line past transmission.
^ Align assembly mountings for engine and transmission.

Note: Torque settings; Refer to Engine , Specifications, Mechanical; Tightening Torques
^ Install right side axle shaft and attach left side axle shaft to transmission:
^ Install front exhaust pipe
^ Install power steering pump:
^ Reconnect electrical connections and check routing:
^ Install ribbed belt.
^ Install secondary air injection pump.
^ Install center, left and right insulation trays:
^ Fill system with coolant.

Vehicles without EPC
^ Adjust accelerator cable.

Vehicles with EPC
^ Adapt (match) engine control module to throttle valve control
Continuation for all models
^ If fault memory has been erased or engine control module was disconnected from permanent positive, respective components must be adapted to engine control module and readiness code generated again.
^ Road test vehicle and interrogate all fault memories:
Refer to Diagnostic tester VAS5051; Guided fault finding; Vehicle system test
Observe the valid safety precautions when performing a road test.
^ Read readiness code.

Vehicles with automatic transmission
^ Adapt transmission control module:
^ Test drive vehicle and interrogate fault memory.

Engine, mounting on assembly stand
When working on the engine, it should be secured to the assembly stand support clamp VW313 using the engine and transmission bracket VW540 and supplementary set VW540/1B.