Installing engine - vehicles with four-wheel drive: VW 1.9 TDI (BJB, BLS, BSU)

Installing engine - vehicles with four-wheel drive
Caution
When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:
Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original positions.
Ensure that there is sufficient clearance to all moving or hot components.
Install in reverse order. In the process, note the following:
Check clutch release bearing for wear and renew if necessary.
Clean splines of input shaft and lightly grease them with
grease for clutch plate splines
Electronic Parts Catalogue
.
Check whether dowel sleeves for centring engine/gearbox are fitted in cylinder block and install if necessary.
Rock engine to align engine mountings stress-free. If necessary, also loosen engine mountings on body.
Bolt left drive shaft to gearbox
Running gear, axles, steering
Rep. gr.
40
Drive shafts; Removing and installing drive shaft
.
Install front exhaust pipe with particulate filter
Chapter
.
Vehicles with air conditioner
Install air conditioner compressor
Heating, air conditioning
Rep. gr.
87
Air conditioner compressor; Removing and installing air conditioner compressor
.
Continuation for all vehicles
Install power-assisted steering vane pump.
Install poly V-belt
Chapter
.
Push pipe/hose assembly
A
to stop into slave cylinder bleeder.
Push down clip
arrow
.
Test line by tugging on it.
Remove
hose clamp, up to 25 mm in diameter
3094
from pipe/hose assembly.
Bleed clutch mechanism
Rep. gr.
30
.
Install selector mechanism to gearbox
6-speed manual gearbox 02Q
Rep. gr.
34
Selector mechanism; Removing and installing selector mechanism
.
Install noise insulation
General body repairs, exterior
Rep. gr.
50
Body - front; Noise insulation
.
Install engine control unit
Chapter
.
Install plenum chamber bulkhead
General body repairs, exterior
Rep. gr.
50
Plenum chamber bulkhead
.
With ignition switched off, connect battery earth strap
Electrical system
Rep. gr.
27
Disconnecting and connecting battery
.
Replenish coolant
Chapter
.
Carry out road test and read event memory afterwards
Vehicle diagnostic tester
.
Specified torques
Chapter
“
Assembly overview - assembly mountings
”
Chapter
“
Assembly overview - poly V-belt drive with vane pump
”
Chapter
“
Assembly overview – emission control with catalytic converter
”
Chapter
“
Assembly overview – emission control with diesel particulate filter, engine codes BLS, BSU
”
Drive shafts; Assembly overview - drive shafts
Rep. gr.
40
Assembly overview - drive shaft
.
Hydraulic power-assisted steering; Assembly overview - vane pump
Rep. gr.
48
Assembly overview - vane pump
.
Alternator; Assembly overview - alternator
Rep. gr.
27
Assembly overview - alternator
.
Noise insulation; Assembly overview - noise insulation
Rep. gr.
50
Assembly overview - noise insulation