Installation
WARNING: Numerous leads, hoses, etc., are secured by means of plastic ties. After pulling them tight, cut off the ends as close as possible to the clip. Help to prevent the risk of chafing damage done by sharp edges.
NOTE: The method described applies to a car equipped with water-cooled turbo, intercooler, AC, automatic transmission, catalytic converter, two-stage cooling fan and automatic belt tensioner. The procedure needs to be adapted as appropriate to suit cars to different specifications.
1. Attach lifting sling 83 92 409 to the lifting lugs on the engine such that the centre of gravity is displaced towards the transmission end of the unit. Position the power train over the engine bay and lower it slowly and carefully into position.
NOTE: Pay particular attention to ensure that the following components do not snag:
- Brake lines from ABS unit
- Kickdown cable
- Radiator
Before the power train has been fully lowered, insert the bolt through the LH engine mounting.
Remove the lifting sling.
2. Lift the fan into position and fit the two top screws. Plug the connector into the fan.
3. Raise the car.
- Fit the screw in the bottom of the fan.
- Refit the drain plug in the bottom of the radiator and also the middle infill panel underneath the spoiler.
4. On both sides:
Remove the protective caps from the driveshaft joints and check that there is sufficient grease in the joints.
Engage the two halves of the joints and slide the rubber gaiters into position.
5. Fit the top bolts securing the MacPherson struts to the steering-servo members and torque the top and bottom securing bolts to 78-105 Nm (58-77 ft lb).
Fit the clips on the rubber gaiters. If clips of the non-screw type are used, fit them as shown. Take care not to damage the gaiters.
6. Refit the wheels and lower the car.
7. Tighten the nuts on all engine mountings.
8. Connect the vacuum hose from the charcoal canister to the inlet manifold.
9. Remove the plug from the steering servo pump delivery hose and reconnect the hose to the pump.
Reconnect the inlet hose to the power steering fluid reservoir.
10. Refit the power steering fluid reservoir.
11. Fit the oil cooler. Secure the hoses by ties to the hose for the AC compressor and to the wing (tie and clip).
12. Reconnect the exhaust pipe to the turbo unit.
13. Fit the turbo delivery pipe.
14. Reconnect the bottom radiator hose.
15. Fit the top engine mounting and torque arm.
16. Plug in the connectors for the Lambda sensor. Fit the two clips onto the engine and a new tie around the lifting lug.
17. Fit the AC compressor complete with belt tensioner and coolant hose.
- Torque compressor bolts to 20 Nm (15 ft lb).
- Connect the hose to the water pump, taking care not to damage the lead from the Lambda sensor.
- Fit the compressor drive belt, tension the belt and tighten the locknut. Check the tension of the belt.
- Plug on the connector and make sure that the lead is clear of the pulley.
18. Reconnect the radiator hose to the expansion tank and plug in the connector. Put back the tank and reconnect the expansion hose. Fit a tie around the leads and hoses.
19. Reconnect the gear-selector linkage and secure the cable bushing in the bracket.
20. Remove the plugs and reconnect the oil cooler hoses to the transmission.
21. Refit the clip for the kickdown cable to the gear-selector cable and secure by means of a tie to the pipe from the steering servo pump.
22. Insert the road-speed sensor lead through the grommet in the bottom of the bulkhead and plug on the connector.
23. Reconnect the hoses from the heater box to the engine.
24. Reconnect the vacuum hose from the pressure sensor to the branch piece on the hose from the inlet manifold.
25. Plug the connector into the knock-detector.
26. Insert the pins for the violet/white lead (pin 2) and the grey/red lead (pin 1) into the TSI socket, and fit the socket.
27. Fit the bracket for the LH-system ECU. Make sure that none of the leads is pinched or in a position where it can be damaged by chafing.
28. Plug in all the connectors on the leads in the engine's main wiring loom. Plug in the connector for the LH-system ECU.
29. Fit the LH-system ECU and the ABS-system ECU bracket.
30. Fit the ABS-system ECU in the bracket and secure by means of the strap.
31. Fit the false bulkhead panel and the rubber moulding.
32. Refit the LH cover over the space behind the false bulkhead panel.
33. Secure the wiring loom to the false bulkhead panel by means of a tie. Secure the lead for the knock detector in a suitable way.
34. Reconnect the fuel hose (from the fuel filter) to the fuel-injection rail.
35. Reconnect the fuel return hose to the fuel pressure regulator.
36. Reconnect the throttle cable.
37. Fit the turbo delivery pipe between the turbo unit and the throttle housing. Reconnect the hoses from the transmission and the bypass valve to the pipe.
38. Reconnect the top radiator hose. Fit a tie around the knock-detector lead.
39. Reconnect the HT lead from the coil and the lead from the Hall sensor to the distributor.
40. Fit the solenoid valve and plug in the connector.
41. Fit the air mass meter and plug in the connector. Tie the leads to the hose from the heater box.
42. Refit the battery shelf and terminal block.
- Clip the battery positive lead to the shelf and reconnect it to the terminal block.
- Reconnect the battery negative lead to the earthing point on the wing.
43. Refit the fuel filter.
44. Fit the washer fluid reservoir. Reconnect the hose and plug in the connectors for the fluid-level sensor and pump (red and black).
45. Fit the battery in the shelf and reconnect the leads.
46. Remove the extension pieces from the bonnet (hood) struts.
47. Replenish the coolant, power steering fluid and washer fluid. Pressure test the cooling system.
48. Check the ignition timing and the CO content and adjust as necessary.
49. Test drive the car. Check that all systems are working properly and listen for rattles and noises indicating loose wiring looms, parts, etc. Inspect all hose connections for leaks.
50. Check the fluid level in the automatic transmission, topping up as necessary.