Engine, Installing
Engine, Removing
Special Tools and Workshop Equipment Required:
- Holding fixture -VW 313-
- Engine and Transmission Holder -VW 540-
- Adapter Set for Engine and Transmission Support -VW 540/1B-
- Engine Support Bridge -10-222A- with Bracket for Engine -10-222 A1-.
- Lifting Tackle -2024A-
- Engine Support Adapter -3147- (vehicles with front wheel drive).
- Support -T10062-
- Drip Tray -V.A.G 1306-
- Torque Wrench -V.A.G 1331-
- Torque Wrench -V.A.G 1332-
- Engine/Transmission Jack -V.A.G 1383 A-
- Spring-type clip pliers -VAS 5034-
- Transmission Support -VW 785/1B- (vehicles with all wheel drive)
- Hose Clamps -VAS 3094-
- Grease -G 000 100- (vehicles with manual transmission)
- Cable tie
Torque Specifications:
Caution!!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
- Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
- Ensure sufficient clearance to all moving or hot components.
Installation is performed in reverse order of removal. When doing this note the following:
With Manual Transmission
- Check clutch release bearing for wear and replace if necessary.
- Lubricate clutch release bearing and splining of input shaft with thin coating of grease -G 000 100- (Do not lubricate guide sleeve for release bearing).
- Make sure centering sleeves for engine to transmission are installed in cylinder block. Install if necessary.
- Align engine mount for stress-free installation through shaking movements.
- Replace self-locking nuts -1- for securing engine mount.
NOTE:
When lowering engine, engine mount pin _2- must engage into subframe.
- Install connecting bolts for engine/transmission.
- Tightening Specifications:
- Install the starter, refer to: Service and Repair
- Install generator, refer to: Service and Repair
- Install A/C compressor, refer to: Service and Repair
- Install ribbed belt, refer to: Service and Repair
With AWD
- Fasten the intermediate bearing of the driveshaft to the vehicle floor. Afterwards, remove the -3213- and tighten the bolts using the specified torque.
For manual transmission, refer to: Service and Repair
For automatic transmission, refer to: Service and Repair
- Secure transmission mount to subframe.
- Install intake hose for power steering pump and pressure hose for the power steering system. Refer to: Service and Repair
- Install fuel supply and return lines to fuel rail. Refer to: [1][2]Fuel Delivery and Air Induction
- Install lock carrier with attachments, refer to: Service and Repair
- Connect the left and right front exhaust pipe to the exhaust manifold.
- Install the heat shield/driveshaft.
- Electrical connections and routing.
- Fill with coolant, refer to:
Vehicles With Accelerator Pedal Cable
- Adjust the accelerator pedal cable, refer to:
- Install vacuum diaphragm for Cruise Control System -CCS- (only vehicles with CCS).
- Check power steering fluid level, bleed the steering system and inspect the steering system for leaks, refer to:
- Check headlight adjustment, correct if necessary.
- Perform vehicle system test.
- End vehicle system test, this will automatically erase DTC entries which occurred during the assembly.
- Generate readiness code in conjunction with a road test.
- Perform road test.
NOTE:
- Observe safety precautions that apply to road tests.
- Then perform vehicle system test anew and repair any occuring malfunction if necessary.