Engine, Installing

Installation is reverse of removal, note the following during installation:

-- Check whether centering dowels for engine/transmission are installed in cylinder block, install if necessary.

-- Install intermediate plate onto sealing flange and slide onto dowel sleeves -arrows-.

Fig 1: Identifying Intermediate Plate Alignment Bushings

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Vehicles with manual transmission 

-- Check clutch release bearing for wear, replace if necessary.

-- Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft using G 000 100.

-- Install hydraulic clutch slave cylinder: refer to [For transmission(s) 02J] HYDRAULIC SYSTEM ASSEMBLY OVERVIEW (-item 12-), or refer to [For transmission(s) 0A4] SLAVE CYLINDER , or refer to [For transmission(s) 02M] CLUTCH SLAVE CYLINDER

-- Install selector mechanism. Refer to [For transmission(s) 02E] REMOVAL AND INSTALLATION , or refer to [For transmission(s) 02J] SELECTOR MECHANISM , or refer to [For transmission(s) 0A4] Removal and Installation , or refer to [For transmission(s) 02M] Removal and Installation

-- If necessary adjust gear change cables: refer to [For transmission(s) 02E] DIAGNOSIS AND TESTING , or refer to [For transmission(s) 02J] DIAGNOSIS AND TESTING , or refer to [For transmission(s) 0A4] DIAGNOSIS AND TESTING , or refer to [For transmission(s) 02M] DIAGNOSIS AND TESTING

Vehicles with automatic transmission 

-- Replace lock washer on selector cable anchorage.

-- Install selector cable on transmission, adjust if necessary: refer to [For transmission(s) 09G] SELECTOR LEVER CABLE or refer to [For transmission(s) 01M] Removal and Installation

All vehicles 

-- When installing engine and transmission assembly, make sure sufficient clearance to axle shafts.

-- While raising, carefully guide power steering fluid line past transmission.

-- Align engine and transmission subassembly is transversely so there is a distance between engine mount -1- and engine bracket -2- of approx. 10 mm (installed condition).

Fig 2: Aligning Engine And Transmission Subassembly

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- When bolting mount support arm to engine support and transmission console, engine and transmission mount must not be stressed (aligned parallel to each other).

Tightening torques FASTENER TIGHTENING SPECIFICATIONS 

-- Remove left-hand axle shaft and disconnect right-hand axle shaft at transmission: Removal and Installation

-- Remove front exhaust pipe FRONT EXHAUST PIPE AND CATALYST WITH ATTACHMENTS

-- Remove connecting pipe between charge air cooler and intake manifold with EGR Vacuum Regulator solenoid valve.

-- Install power steering pump: Removal and Installation

-- Check electrical connections and routing: SYSTEM WIRING DIAGRAM

-- Install ribbed belt RIBBED BELT TENSIONER

-- Install sound dampening tray: Description and Operation

Fig 3: Identifying Sound Dampening Tray, Rivets & Screws

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Fill with engine coolant COOLANT, DRAINING AND FILLING