Engine, removing and installing: Installing

NOTE:

When carrying out repairs, always replace seals and gaskets as well as self-locking nuts and bolts which have a specified tightening angle.

Installation is carried out in the reverse order, when doing this note the following:

Check whether the dowel sleeves for centering engine/transmission are in the cylinder block, install if necessary.

Fig 1: Identifying Intermediate Plate, Sealing Flange And Dowel Sleeves

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engage intermediate plate on sealing flange, and press onto dowel sleeves (arrows).
Make sure that clutch plate is properly centered.
Check clutch release bearing for wear, replace if necessary.
Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with G 000 100.

Bleed clutch system:

Refer to 30 CLUTCH

Before securing transmission to engine, insert transmission bracket behind right-hand drive axle flange.

Fig 2: Removing/Installing Bolt & Small Cover Plate

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slide in small cover plate -2- so that bottom lug on crankcase engages, and secure at the top with bolt -1- (wrench width = 10 mm).

Fig 3: Identifying Engine Supports Bolts & Distance Between Engine Console & Support Arm

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Align engine mounts so that distance -a- , (measured on right-hand mount) is approx. 13 mm. It should be possible to insert a 12 mm flat iron bar without difficulty (e.g. special tool 2011). To move engine in engine console, bolts -b- on left and right engine supports must be loosened about 2 turns. Adjusting engine mounts. Refer to Engine mounts, adjusting
Attach selector cables to transmission and adjust:

Refer to 34 MANUAL TRANSMISSION - CONTROLS, HOUSING ; Removing and installing selector cables

Installing power steering vane pump:

Refer to 48 STEERING ; Removing and installing pump

Vehicles with air conditioner:

Fig 4: Knocking Back Threaded Bushings For Mount Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To facilitate installing the air conditioner compressor, knock back threaded bushings -B- for mount bolts -A- slightly in the direction indicated (arrow).

All vehicles:

Install ribbed belt. Refer to Installing ribbed belt .
Install front exhaust pipe. Refer to Front exhaust pipe, removing and installing .

NOTE: Avoid excessive bending of the de-coupling element (no more than 10°).

Stress-free alignment of exhaust system. Refer to Exhaust system, aligning free of stress .
Connect coolant hoses. Refer to Figure.
Connect vacuum hoses. Refer to Figure
Fill up with coolant. Refer to Filling .

NOTE:

Drained-off coolant may only be used again if the original cylinder head and cylinder block are re-installed.
Do not use coolant that is dirty or contaminated.

Check the oil level before starting engine. Refer to Oil level, checking .
Electrical connections and routing:

Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations

After connecting battery terminals, enter anti-theft code for radio

Refer to Radio operating instructions

WARNING:

If a battery charger is used to give the engine an assisted start, there is a risk that the control units in the vehicle will be damaged.

Close electric windows in front doors all the way to their top positions using electric switches.
Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic one-touch function.
Set clock to correct time.
Perform adaption of throttle valve control module:

Refer to

24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMU
24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): ATC
24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWP
24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): BEA

; Performing adaptation of throttle valve control module

Interrogate malfunction memory:

Refer to

01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMU
01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): ATC
01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWP
01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): BEA

; DTC memory, checking and erasing

NOTE: DTCs will have been stored in the memory because connectors have been disconnected. Therefore interrogate and erase DTC memory after installing engine.