REMOVING THE ENGINE

PREPARING ENGINE PARTS

Wipe injector clean and glue small "o" rings (replace as needed) onto injector tips with cyano-acrylate.

Allow oil to drain from the A/C compressor. (Only if R134A gas is to be retrofitted).

Drill hole in the fuel pressure regulator bracket (Fig 1). Remove the pipe that went to the right side cylinders and fit supplied blank off using 14.5 squeeze clamp. Remove protection sleeve from the removed pipe.

Shorten the left side fuel hose to 280mm (replace as needed). Also shorten the protection sleeve.

Shorten the alternator bracket to Fig. 2 and straighten.

Disconnect the power steering pump brackets from the pump and flip both brackets over 180 deg. Also rotate the pump through 90 deg. (Note: requiring all bolts to be removed – do not allow pump to split).

Replace alternator bearings. (Recommended).

Drill hole in the right side exhaust bracket and cut off sections of the left bracket (Fig. 11a & 11b)

Check condition of the starter bush in gearbox casing by checking for excessive play.

FITTING THE NEW ENGINE

Install clutch plate and pressure plate and align properly.

Fit plastic inserts to injectors and fit injectors to the fuel rail. (Note: with fuel rail on left side, pointing forward, electrical connectors must point up). Insert injectors into the intake manifold and fit injector support. (Use loctite on bolts). 5 mm Allen.

Fit fuel pressure regulator to tappet cover bolt (right side flywheel end).

Connect pipe to fuel rail (Sleeve to remain on pipe and 14.2 clamps to be used).

Connect vacuum hose from intake manifold to fuel pressure regulator (340mm length vacuum hose needed).

FOR AIR CONDITIONED MODELS

Fit compressor to upper side of accessory mounting bracket and tighten down (fit sliding bush, do not put spacer washers under right side compressor mounting blocks).

Fit alternator using supplied nut, bolt, washer and 13x1145 belt. Tension using modified adjusting bracket fitted to air conditioner compressor ear.

Fit power steering pump to bush on lower side of accessory mounting bracket and tensioning bracket. Fit 13x925 belt.

FOR NON AIR CONDITIONED MODELS

Fit alternator to bush with spacer on outside. Use V4362 belt.

Fit power steering pump and V4352 belt as above.

Remove water pump pulley and refit with spacer on outside of pulley. Fit V4372 belt.

MODIFICATION TO THE VEHICLE

Remove welded on power steering reservoir bracket from rear of engine bay. Cut lower section of the bracket off and bolt to the water bottle bracket (Fig. 3) using and angle grinder.

Cut 20 – 30 mm off rear section of 2.1 air cleaner mounting bracket on the right side of the engine compartment. Drill holes as per Fig. 5 and fit water bottle bracket.

Fit coil to right side of engine compartment front panel using self-tapping screw from 2.1 heat shield. (Fig 6). Drill 5/32 hole.

Remove ECU and bracket from left D-post cavity.

Fit TCI unit (supplied) below coil.

Remove plastic water manifold and rubber hose on front right of engine compartment next to the gearbox.

Cut short water pipe removed from right side plastic radiator pipe in half and fit halves to the supplied plastic water pipe.

Fit supplied water pipe extension to water hose. Clip pipe extensions into place on front panel and secure with cable ties. (Fit with short ends pointing rearwards).

Pull heater hose routed over gearbox back and shorten by 280mm. Route this pipe straight back just below water pipe extensions.

Join the 280 mm section to heater pipe that went straight back and now route this pipe over the gearbox (heater pipes are effectively swapped around).

Slide complete snorkel out of right D-post and fit to left D-post.

Fit supplied lower elbow to the snorkel in the left cavity.

Drill holes for air filter bracket on left side on engine bay (Fig. 7).

Unclip power steering metal lines from front right engine bay.

Bolt right side engine carrier into engine bay (Fig 4). Fit 25mm spacer to front and bolt to the rear.

Re-attach power steering lines to clips.

Fit bracket to air filter housing (use nuts and bolts from 2.1 muffler supports). Route air conditioner pipes and wiring harness as Fig. 12 and fit housing. Secure with 2.1 heatshield self-tappers. (Use 1299 on filter inlet hole and remove element to assist in fitting of snorkel).

Remove accelerator cable and replace with new supplied cable.

Route harness around engine bay starting from connector box on left side, as per Fig. 6 & 7. Feed ECU plug section forward along left member.

Remove accelerator bracket from gearbox bell housing.

FITTING THE NEW ENGINE

Lift engine until gearbox input shaft can be entered. Push home and fit bottom nuts to studs.

Lift further and align right engine mounting and enter bolt.

Attach left side carrier to body. Fit 25mm spacers at the front and bolt to the rear.

Enter right Allen cap bolt and fit nuts to top gearbox / engine joint.

Tighten bottom nuts to studs.

Tighten top nuts.

Connect radiator water pipes front right of engine compartment.

Fit water bottle and connect water pipes.

Connect heater pipe from the back of cylinder head to pipe routed over gearbox.

Fit supplied grommet to large hole in engine compartment at right of electrical connector box.

Fit supplied fuel pipe form fuel rail to supply spigot. First slide sleeve over pipe. Route as Fig. 14.

Feed ECU / relay branch of wiring harness from right side of engine compartment connector box, along left long member, through firewall into seat cavity.

Connect up harness connectors to engine.

Secure harness into cable ties.

Fit ECU and relay holder to firewall with self-tapping screws (Fig. 9).

Remove switch from power steering coupling and fit supplied blank off (10x1.0x15 mm).

Fit power steering reservoir to mounting and route pipes so that they are tension free and do not foul. Tighten bolts.

Feed alternator harness form air filter housing along the back of the engine compartment and connect to the alternator together with the harness from the starter. Rear harness to be secured high up to clear exhaust.

Connect accelerator cable. Trim new cable 100mm and replace front throttle screw with supplied bolt, which is 10.mm longer.

EXHAUST FITTING

On vehicles with adjustable tail pipe loosen tail pipe to enable it to be rotated.

With fixed tail pipe, cut off tail pipe outboard of clamp.

Fit muffler loosely to down pipe (use sealing ring). Adjust such that there is clearance to pulleys and engine carrier.

Fit right support bracket and align such that the rubber mounts are not under tension. Adjust muffler level and tighten up all bolts. Fit and tighten strap.

Adjust tail pipe of weld on in correct position.

Note: some adjustment may be required to the rear valance to clear the muffler. Simply reach under the valance with your hands and pull slightly towards you till you have adequate clearance from the muffler.

STARTING

Fill sump with 4.5 liters API SG oil.

Top up power steering reservoir.

Remove front grill and bleed cooling system as follows:

The proportion of anti-freeze must not exceed 60% as frost protection and cooling effects are reduced with greater proportions of anti-freeze. Phosphate free anti-freeze is no longer necessary.

Set heater control to max.

Loosen bleed screw in engine compartment

Open bleed screw in engine compartment.

Fill expansion tank to the brim.

Start engine.

With approximately 2000 rpm, top up until coolant issues from the radiator bleed screw, then tighten screw.

Fill expansion tank to brim and close filler cap.

Switch off ignition.

Raise vehicle approximately 40 cm at front under cross member with trolley jack and wooden underlay or with a two-pillar 6-t hoist V.A.G. 1372.

Re-start engine.

At engine speed of approximately 2000 rpm, open bleed screws on radiator and expansion tank.

Close bleed screw on radiator when coolant issues.

Add coolant if necessary and close expansion tank filler cap.

Switch off engine.

Close bleed valve and engine compartment.

Fill top-up reservoir up to brim. With the engine cold, the engine level must be between the min. and max. mark.

Plug 1551 in under rear seat.

Set basic timing to 6 deg. And CO to 1% (6% marked on engine timing cover with small hole).

RECONNECTING THE AIR CONDITIONER