Engine, securing to engine stand

Fig 1: Identifying Special Tools - Engine, Securing To Engine Stand

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 2: Identifying Lifting Tackle 3033 & VAS 6100

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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.

Fig 3: Securing Engine/Transmission Support VW 540 With Parts From Engine And Transmission Support Supplement VW 540/1B To Cylinder Block

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure engine and transmission support VW 540 with parts from engine and transmission support supplement VW 540/1B 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 %.

Fig 4: Identifying Bolts On Engine/Transmission Flange

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Securing engine to transmission

A - dowel sleeves for centering

Item no.	Bolt	Nm
1	M12 x 55	80
2 1)2)	M10 x 40	40
3 1), 6	M12 x 55	80
4 2), 9	M10 x 45	40
5	M12 x 65	80
7, 8	M10 x 50	40
10	M12 x 70	80

1) Bolt with M8 stud

2) Bolt is only used to secure starter to transmission

Fig 5: Identifying Bracket For Bevel Box & Bolts

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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.

Fig 6: Locating Engine Carrier Bolts (Engine Side)

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Tighten bolts (use new bolts) for engine support to engine console (arrows)...

Fig 7: Locating Engine Carrier Bolts (Transmission Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

..and transmission support to transmission mount (arrows) initially finger tight.

NOTE: The bolts are tightened to final torque only after adjusting the engine mountings. Refer to Engine mountings, checking and adjusting .

Remove engine bracket T10102 from engine.
Install axle shafts and tighten bolts hand tight.

Refer to 40 FRONT SUSPENSION

NOTE: Axle shafts must be installed prior to further assembly.

Fig 8: Securing Pendulum Support At Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure pendulum support at transmission (arrows -B-). Use new bolts.

Fig 9: Identifying Sealing Ring In Driveshaft Flange

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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.

Fig 10: Identifying Pendulum Support On Subframe

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Secure pendulum support at subframe (arrows -A-). Use new bolts.

Fig 11: Identifying Bevel Gear Transfer Case Flange Bolts

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Secure driveshaft with flexible coupling to flange of bevel box (arrows).
Tighten axle shaft bolts.

Refer to 40 FRONT SUSPENSION

Perform further installation in reverse order. Pay attention to the following:

Install exhaust system and align it free of stress. Refer to Exhaust system, aligning free of stress .
Install selector lever cable.

Refer to 34 MANUAL TRANSMISSION - CONTROLS, HOUSING

Install bracket for ancillary units. Refer to Bracket for ancillary units, removing and installing .
Drive back respective bushings for securing bolts slightly to facilitate installation of Generator, power steering pump and A/C compressor.
Install Generator.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Install air conditioning compressor.

Refer to 87 AIR CONDITIONING

Install radiator cowl. Refer to Radiator, removing and installing .
Install power steering pump.

Refer to 48 STEERING

Install body brace and cross piece.

Refer to 40 FRONT SUSPENSION

Install poly V-belt.
Adjust engine mountings. Refer to Engine mountings, checking and adjusting .
Connect electrical connections and check routing.

Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations

Connect Ground strap to battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Check oil level. Refer to Oil pump, component overview .

CAUTION:

Never use the battery charging equipment for boost starting. There is a danger of damaging the vehicle control modules.

Fill cooling system. Refer to Cooling system, draining and filling .

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

Component		Nm
Bolts/nuts	M6	10
	M8	20
	M10	45
	M12	65
Except for the following:
Pendulum support to transmission		40 + 90° 1)2)

1) Replace nuts and bolts

2) 90° equals one quarter turn

Component		Nm
Pendulum support to subframe		20 + 90° 1)2)
Flexible coupling to bevel box		60
Front exhaust pipe to exhaust manifold		40 1)
Front exhaust pipe to catalytic converter		25
Wire guide to subframe		10
Axle shaft heat shield to bevel box		23
Bracket for coolant pump for After-run coolant pump -V51- to cylinder block		20
Wiper arms to wiper shafts		16
Bracket for secondary air pump	M6	10
to engine	M8	20

1) Replace nuts and bolts

2) 90° equals one quarter turn