Engine, Installing: Procedure

WARNING: This page is about a different car, the 2015 Volkswagen Passat. 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: Installing 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 figure 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[For transmission(s) 0A4] Clutch [For transmission(s) 02Q] Clutch [For transmission(s) 02E] Clutch .

-- 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 subassembly into the body.

-- Install the bolts -arrows- for the engine mount by hand until it is in position.

Fig 3: Identifying Engine Mount

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-- Install the bolts -arrows- for the transmission mount by hand until it is in position.

Fig 4: Identifying Bolts

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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 [For transmission(s) 0A4, 02E, 09G, 02Q] Battery, Starter, Generator, Cruise Control .

-- 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 GENERAL INFORMATION GENERAL INFORMATION .

-- Install the Air Conditioning (A/C) compressor, refer to REMOVAL AND INSTALLATION .

-- Install the ribbed belt, refer to RIBBED BELT .

-- Install the Engine Control Module (ECM), refer to Engine Control Module -J623-, REMOVING AND INSTALLING or.Engine Control Module -J623- WITH PROTECTIVE HOUSING, REMOVING AND INSTALLING .

-- Install the right drive axle heat shield, refer to GENERAL INFORMATION GENERAL INFORMATION .

-- Install the subframe, refer to GENERAL INFORMATION GENERAL INFORMATION .

-- Install the Differential Pressure Sensor -G505-, refer to Differential Pressure Sensor -G505-, REMOVING AND INSTALLING .

-- Install the selector mechanism from the transmission, refer to [For transmission(s) 0A4] Controls, Housing [For transmission(s) 02Q] Controls, Housing [For transmission(s) 02E] Controls, Housing .

-- Connect the clutch slave cylinder, refer to [For transmission(s) 0A4] Clutch [For transmission(s) 02Q] Clutch [For transmission(s) 02E] Clutch .

-- Bleed the clutch hydraulic, refer to [For transmission(s) 0A4] Clutch [For transmission(s) 02Q] Clutch [For transmission(s) 02E] Clutch .

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

-- Install the battery tray, refer to [For transmission(s) 0A4, 02E, 09G, 02Q] Battery, Starter, Generator, Cruise Control .

-- Wire routing, refer to [For transmission(s) 0A4, 02E, 09G, 02Q] Wiring Wiring and => appropriate System Wiring Diagram Information.

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

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

-- Install the fuel filter, refer to Fuel Supply .

-- Install the noise insulation, refer to NOISE INSULATION .

-- Remove the right and left front wheel housing liners, refer to WHEEL HOUSING LINER .

-- Install the front wheels, refer to Wheels, Tires and Vehicle 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 5.

Fig 5: Connecting Coolant Hose Coupling

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

NOTE:

Do not reuse used coolant.