Engine, Installing: Procedure

WARNING: This page is about a different car, the 2015 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Replace the bolts that were tightened with an additional turn after removing them.

Replace the self-locking nuts and bolts, sealing rings, seals and O-rings after removing.

The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.

Secure all hose connections with hose clamps.

During installation, all cable ties must be installed at the same location.

-- Install the intermediate plate, refer to Fig 1.

Fig 1: Identifying Intermediate Plate

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-- If the alignment sleeves -A- for centering the engine and transmission are missing inside the cylinder block, then install the sleeves.

Fig 2: Identifying Bolts On Engine/Transmission Flange, Removal

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NOTE: The illustration shows a vehicle with a manual transmission.

-- If a needle bearing is installed in the crankshaft, remove the needle bearing, refer to CRANKSHAFT NEEDLE BEARING, REPLACING .

-- If the clutch release bearing is worn, replace it, refer to CLUTCH SLAVE CYLINDER WITH RELEASE BEARING .

-- Lightly lubricate transmission input shaft splines with clutch disc connection lubricating grease.

-- Check the clutch plate alignment.

-- Tighten the transmission to the engine.

-- Install the transmission support.

-- Lift the engine/transmission assembly using the Engine Support T10497.

-- Guide the engine/transmission assembly into the body.

-- Remove the bolts -arrows- for the engine mount -1- completely.

Fig 3: Identifying Engine Mount

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Vehicles with Triple Transmission Screw Connection

Fig 4: Identifying Bolts

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-- Remove the transmission mount bolts -arrows- completely.

Vehicles with Double Transmission Screw Connection

Fig 5: Identifying Bolts

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-- Remove the transmission mount bolts -arrows- completely.

NOTE: The bolts are only tightened to final specification after the assembly mounts have been adjusted, refer to SUBFRAME MOUNT, ADJUSTING .

-- Remove the Engine Support T10497 from the engine.

-- Install the starter, refer to STARTER .

-- Install the Charge Air Cooling Pump - V188-, refer to CHARGE AIR COOLING PUMP -V188- .

-- Install the air guide pipe, refer to OVERVIEW - CHARGE AIR SYSTEM .

-- Install the intake tube, refer to OVERVIEW - TURBOCHARGER .

-- Install the front exhaust pipe, refer to FRONT EXHAUST PIPE .

-- Install drive axles, refer to FRONT SUSPENSION .

-- Install the A/C compressor, refer to AIR CONDITIONING .

-- Install the ribbed belt, refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Install the engine control module, refer to ENGINE CONTROL MODULE -J623- .

-- Install the right driveshaft heat shield, refer to HEAT SHIELD .

-- Install the subframe, refer to FRONT SUSPENSION .

-- Install the Differential Pressure Sensor -G505-, refer to DIFFERENTIAL PRESSURE SENSOR -G505- .

-- Install the selector mechanism from the transmission, refer to INSTALLING .

-- Connect the clutch slave cylinder, refer to CLUTCH SLAVE CYLINDER WITH RELEASE BEARING .

-- Bleed the clutch hydraulic, refer to CLUTCH HYDRAULIC HOSE/LINE OR PIPE .

-- Adjust the subframe mount, refer to SUBFRAME MOUNT, ADJUSTING .

-- Install the battery tray, refer to BATTERY TRAY .

-- Wire routing, refer to WIRING and appropriate Wiring Diagram.

-- Connect the vacuum hoses, refer to CONNECTION DIAGRAM - VACUUM SYSTEM .

-- Install the air filter housing, refer to AIR FILTER HOUSING .

-- Install the fuel filter, refer to FUEL SUPPLY .

-- Install the noise insulation, refer to EXTERIOR EQUIPMENT .

-- Remove the front right and left wheel housing liners, refer to EXTERIOR EQUIPMENT .

-- Install the front wheels, refer to WHEELS, TIRES, WHEEL ALIGNMENT .

-- Check the oil level. .

CAUTION: There is a risk of destroying control modules with excess voltage.

Do not use a charger as a starting aid.

-- Bleed the fuel system, refer to FUEL SYSTEM, FILLING/BLEEDING .

-- Attach the coolant hoses to the heater core, refer to Fig 6.

Fig 6: Connecting Coolant Hose Coupling

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-- Fill the coolant, refer to COOLANT, DRAINING AND FILLING => .

NOTE: Do not reuse used coolant.