| 1. Check the engine mounts, fuel, oil pipelines and water hoses for wear and cuts, and replace if necessary. |
| 2. Check the thickness and condition of the friction linings clutch disc. If heavy wear and high mileage clutch replaced completely. If you press the clutch release bearing publishes noise, replace the bearing. |
| 3. Check the wear on the clutch release bearing and replace if necessary (see. Section 3.2). |
| 4. Clean the clutch and drive shaft splines, spread a thin layer of grease MoS 2 or VAG-Fett G000100. |
A warning  The guide bushing off not lubricated.
|
| 5. Check the cylinder block guides for centering engine and gearbox, if necessary, install it. |
| 6. Push in the guides intermediate plate and coat in some places fat grease, glued to the cylinder block. |
| 7. Carefully insert the motor into the engine compartment. Lifting done with great caution to avoid damage to the drive shaft, the clutch or the body. |
| 8. Screw the new self-locking nuts of the engine mounts. The nuts are not tightened. |
| 9. Attach the engine to the gearbox, rotating the drive shaft of the box so that he went into the clutch and flywheel. You can also rotate the crankshaft at central bolt. |
10. Tighten the bolts connecting the engine to the gearbox the following torque:
- Bolts M8 - 20 Nm;
- Bolts M10 - 60 Nm;
- Bolts M12 - 80 Nm. |
| 11. Tighten the flywheel housing to 20 Nm. |
12. seeling without straining the engine set. Finally tighten the engine support the following torque:
- Support of the engine on the carrier beam M10 - 65 Nm;
- Engine support right at the cylinder 50 Nm 90 ?� (1/4 turn) further;
- Support of the engine at the rear of the cylinder M8 - 20 Nm;
- Support of the engine at the rear of the cylinder M10 - 45 Nm;
- Engine support rear gearboxes M8 - 20 Nm. |
| 13. Unscrew the assembly tool VW-3230 from the cylinder. |
| 14. Fit the fuel line (black) on the union, and a bypass line (blue) to the fuel distributor, fix collars. Do not confuse the piping supply and return fuel. |
| 15. If removed, the screw refrigeration compressor and pump power steering. Tightening torque, power steering pump - 20 Nm. Push and pull the V-belt (see. Subsection 2.12.1). |
| 16. Remove from the transmission housing mounting studs or screw M8h22. Close the hole with a rubber stopper and check the correct position of the push rod lever clutch. |
| 17. Secure the collector voltage without front exhaust pipe. |
| 18. Install the coolant tube between the thermostat and water pump, coolant hose from the heat exchanger. |
| 19. Install the heat sink (see. Subsection 2.16.2.1). |
20. Connect all coolant hoses, clamps fix:
- The upper radiator hose to the fitting of a cooling liquid;
- The lower hose on the oil cooler;
- Hose to the thermostat housing coolant; Two hose expansion tank and heat exchanger on the coolant pipe. |
| 21. push the harness through the engine intake manifold. |
22. firmly connected, according to the notation of duct tape, electric wires following tips:
- Plug a potentiometer;
- Plug the throttle potentiometer;
- Multi-compound injection valves;
- Plug valve of stabilization of idling;
- Plug valve cold start;
- Plug Hall sensor on the ignition distributor;
- Plug connection for lambda probe under the machine on the bracket mounted units, to the right;
- Plug the pressure sensor on the body of the power steering, if any;
- Two plugs of both coolant temperature sensor;
- Plug the oil pressure sensor on top of the oil cooler and the left end side of the cylinder head;
- Earth wire cylinder head cover;
- Thick wire (B), and a thin blue line (P) of the generator, to impose a gray protective cap. |
| 23. Secure the electrical wiring in their original locations cable clamps. |
| 24. Establish the bottom mudguard of a motor compartment (see. Section 2.4). |
| 25. Lower the car. |
| 26. To establish a cover of the distributor of ignition and to put all the wires to the spark plugs. |
| 27. Install the air hose with the valve of stabilization of idling between the air filter and throttle body. Put on hoses and clamps secure. |
| 28. Screw the valve of stabilization of idling with the bracket to the intake manifold. |
| 29. Set the throttle cable to the fence and adjust (see Fig. Subsection 2.17.5). |
30. Connect all the vacuum hoses to the engine:
- Hose heating receiving air throttle;
- A hose of solenoid valve of a tank with the activated carbon on the throttle;
- Hose Digifant control unit to throttle the screen;
- A hose on the brake booster check valve. |
| 31. Check the oil level in the engine and the transmission, top up if necessary. |
| 32. Check the coolant concentration, top up if necessary (see. Subsection 2.16.3). |
| 33. Connect a wire of "weight" (-) to the battery. Enter anti-theft code, program the radio stations and set the clock. |
A warning A battery connected only with the ignition off, otherwise fail control unit fuel injection system.
|
| 34. Warm up the engine to operating temperature, check again the oil level and coolant leaks. |
| 35. Check the ignition timing (see. Subsection 2.14.6). |
| 36. Check the idle speed and CO content (see. Subsection 2.18.1). |
| 37. Check the adjustment of the headlamp (see. Subsection 10.19.4). |
