Engine, Installing

WARNING: This page is about a different car, the 2006 Volkswagen New Beetle, 2005 Volkswagen New Beetle, and 2004 Volkswagen New Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Installation is performed in the reverse order of removal, noting the following:

WARNING:

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Route lines of all types (e.g. for fuel, hydraulic, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
Ensure sufficient clearance to all moving or hot components.

-- Insert new centering sleeves for centering engine/transmission in cylinder block.

-- Engage intermediate plate at sealing flange and slide onto alignment bushings -arrows-.

Fig 1: Identifying Intermediate Plate Alignment Bushings

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

With Manual Transmission

-- Lightly coat the input shaft splines with grease G 000 100.

-- Clutch and clutch mechanism, checking and installing [For transmission(s) 02J] Description and Operation or to [For transmission(s) 0A4] Description and Operation or to [For transmission(s) 02M] Description and Operation .

With Automatic Transmission

-- Lightly coat the outer splines of the gear shaft with grease G 000 100.

Continuation for All

-- When installing the engine/transmission subassembly, make sure there is sufficient clearance to the other components.

-- While doing this, route the power steering pressure line on the transmission.

-- Align the powertrain mounts POWERTRAIN MOUNT, ALIGNING .

-- Secure the engine and transmission POWERTRAIN MOUNT TIGHTENING SPECIFICATIONS .

With Manual Transmission

-- Install the hydraulic clutch slave cylinder [For transmission(s) 02J] Description and Operation or to [For transmission(s) 0A4] Description and Operation or to [For transmission(s) 02M] Description and Operation .

-- Install the shift mechanism; if necessary adjust the selector lever cable:

[For transmission(s) 02J] Removal and Installation or to [For transmission(s) 0A4] Removal and Installation or to [For transmission(s) 02M] Removal and Installation

With Automatic Transmission

-- Install the selector lever cable [For transmission(s) 02E] Removal and Installation .

-- Install the subframe Removal and Installation .

With Air Conditioning

WARNING:

The air conditioning refrigerant circuit must not be opened.

NOTE:

To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

To facilitate installation of the engine without having to open the refrigerant circuit:

-- Remove the A/C compressor from the lock carrier and install the compressor Removal and Installation .

-- Install the oil dipstick inlet spout.

-- Install the generator Removal and Installation .

Continuation for All

-- Install the right drive axle, and install the left drive axle onto the transmission Removal and Installation .

-- Install front exhaust pipe EXHAUST SYSTEM COMPONENTS .

-- Install the power steering pump Removal and Installation .

-- Electrical connections and routing General Information .

-- Install ribbed drive belt RIBBED DRIVE BELT .

-- Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .

-- Install the center, left and right noise insulation Description and Operation .

-- Install battery Removal and Installation .

-- Perform vehicle system test using Vehicle Diagnosis, Testing and Information System VAS 5051 "Guided Fault Finding".

-- End vehicle system test, this will automatically erase DTC entries which occurred during the assembly.

Observe safety precautions that apply to road tests.

-- Perform test drive.

-- After that perform vehicle system test anew and repair any occurring malfunctions.