Page 11 of 20
10-8
- Unbolt hydraulic pump from mounting bracket.
CAUTION!
Hydraulic lines should remain connected.
- Unscrew bolts and secure A/C compressor to
one side with wire.
CAUTION!
Disconnect at mounting points only.
DO NOT open the air conditioning refrigerant
circuit.
Set the A/C compressor aside carefully.
Refrigerant lines kink easily.
The A/C refrigerant circuit must only be
opened by specially trained technicians
using the proper tools and equipment.
- Remove bolts securing exhaust manifold and
front exhaust pipe at top.
- Disconnect battery positive (B+) cable from
starter at right of engine below exhaust manifold.
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Page 14 of 20
10-10
Mounting engine cylinder block on assembly
stand
CAUTION!
DO NOT have the cylinder block mounted to the assembly stand
while measuring the cylinder bores (Repair Group 13). The cylinder
block is deformed by its own weight under these conditions and
such stress will result in false measurements that are not accurate
after the tension has been relieved. - Mount engine to stand using holding fixture VW 540 along with VW
540/2.
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Page 15 of 20
10-11
Installing
The engine is installed in the reverse order of
removal, with the addition of the following special
conditions and steps:
WARNING!
Do not re-use any fasteners that are worn or
deformed in normal use. Many fasteners are
designed to be used only once and become
unreliable and may fail when used a second
time. This includes, but is not limited to, nuts,
bolts, washers, self-locking nuts or bolts,
circlips and cotter pins. Always follow
recommendations given in this publication.
Always replace these fasteners with new
parts.
- Check that alignment sleeves for centering
engine and transmission are properly installed in
cylinder block. Install sleeves if necessary.
- Always install new seals and gaskets.
- Check centering of clutch disc, if necessary.
- Check clutch release bearing for wear and
replace if necessary.
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Page 17 of 20
10-12
- Allow stop of torque support to move down onto
rubber block under its own weight; tighten bolts
to 45 Nm (33 ft lb).
- Align exhaust system free of stress Repair
Group 26.
- Adjust accelerator pedal cable Repair Group
20.
- Re-fill engine cooling system Repair Group
19.
- Drained coolant may only be re-used provided
the cylinder block or the cylinder head was not
replaced.
- Check oil level before starting engine.
- Short blocks are supplied without bushing in
crankshaft. For vehicles with automatic
transmission, tap bushing into place before
installing drive plate.
- Check reconditioned engines with manual
gearbox to determine whether needle bearing is
installed in crankshaft; install if necessary.
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