Engine, Securing to Engine Stand
Engine, securing to engine stand
Special tools and equipment
^ Engine and transmission support VW 540
^ Engine and transmission support supplement VW540/1B
^ Lifting tackle 3033
^ Engine stand VAS 6095
^ Workshop crane VAS 6100
Not illustrated:
^ Bolt M12 x 160
Work sequence
- Attach lifting tackle 3033 to engine and workshop crane VAS 6100 as shown in illustration.
- Lift engine off engine bracket T10102 using workshop crane VAS 6100.
- Secure engine and transmission support VW 540 with parts from engine and transmission support supplement VW 540/1 B to cylinder block.
Note:
Use the M12 x 160 bolt to secure the lower right arm (arrow).
- Fasten engine to engine and transmission support VW 540 for assembly work.
Installing
Installation is performed in reverse order of removal. Note the following:
Note:
^ On assembly, replace the self-locking nuts and bolts that are tightened by turning through to a specified angle, as well as oil seals and gaskets.
^ Secure all hose connections with the correct type of hose clamps (same as original equipment).
- Check whether dowel sleeves for centering engine/transmission assembly are installed in cylinder block; install dowel sleeves if necessary.
- Bolt transmission to engine using new bolts.
Note:
^ Tightening torques only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
^ Additional lubricant such as engine oil or transmission oil may be used, but do not use lubricant containing graphite.
^ Do not use degreased parts.
^ Tolerance for tightening torques: ± 15%.
Securing engine to transmission
A - dowel sleeves for centering
- Install bracket -A- for bevel box; note following procedure:
- Initially tighten bolts -1- to 3 Nm.
- Tighten bolts -2- to 35 Nm
- Tighten bolts -1 - to 45 Nm.
- Guide engine/transmission assembly into body.
- Tighten bolts (use new bolts) for engine support to engine console (arrows)...
- ...and transmission support to transmission mount (arrows) initially finger tight.
Note:
The bolts are tightened to final torque only after adjusting the engine mountings.
- Remove engine bracket T10102 from engine.
- Install axle shafts and tighten bolts hand tight.
Note:
Axle shafts must be installed prior to further assembly.
- Secure pendulum support at transmission (arrows -B-). Use new bolts.
- Push engine/transmission assembly toward bulkhead. Journal of bevel box must be simultaneously inserted horizontally and carefully into flange of driveshaft.
CAUTION
The oil seal (arrow) in the flange of the driveshaft must no be damaged when installing the engine/transmission assembly. The driveshaft must be replaced if the oil seal is damaged.
- Secure pendulum support at subframe (arrows -A-). Use new bolts.
- Secure driveshaft with flexible coupling to flange of bevel box (arrows).
- Tighten axle shaft bolts.
Perform further installation in reverse order. Pay attention to the following:
- Install exhaust system and align it free of stress.
- Install selector lever cable.
- Install bracket for ancillary units.
- Drive back respective bushings for securing bolts slightly to facilitate installation of Generator, power steering pump and A/C compressor.
- Install Generator.
- Install air conditioning compressor.
- Install radiator cowl.
- Install power steering pump.
- Install body brace and cross piece.
- Install poly V-belt.
- Adjust engine mountings.
- Connect electrical connections and check routing.
- Connect Ground strap to battery.
- Check oil level.
CAUTION
Never use the battery charging equipment for boost starting. There is a danger of damaging the vehicle control modules.
- Fill cooling system.
Note:
^ Drained coolant may only be used again if the original cylinder head or cylinder block are reinstalled.
^ Contaminated or dirty coolant must not be used again.
Tightening torques
