Engine, removing and installing: Notes

WARNING: This page is about a different car, the 2006 Audi A4, 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Engine, Removing And Installing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and equipment

10-222A Engine support bridge
2024A Engine Sling
3147 Engine support adapter
3299 Ribbed belt installation tool with 3299/1 claw for tensioner

VAG1306 Drip tray for VAG1202A
VAG1383A Engine/transmission hoist

Fig 2: Identifying Special Tools - Workshop Hoist V.A.G 1202 A

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VAG1202A Workshop crane

VAS 6100 Workshop crane

Fig 3: Support T10062

Courtesy of VOLKSWAGEN UNITED STATES, INC.

T10062 Support
Oil receptacle

Removing

NOTE:

Engine is removed toward the front without transmission and with the lock carrier removed.
All cable ties opened or cut during engine removal must be reinstalled at the same locations.
Heat boots, which are removed during engine removal must be reinstalled at the same locations when re-installing engine.
Drained coolant must be stored in a clean container for disposal or reuse.

Vehicles with automatic transmission

Shift selector lever into position "N".

All

WARNING:

Observe safety precautions when disconnecting the battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Fig 4: Identifying Plenum Chamber Cover & Removing Rubber Seal

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Pull off rubber seal of plenum chamber cover in direction of arrow.
Remove cover -1- toward front.

See Caution before beginning repairs on the electrical system. Refer to Engine, removing and installing

Fig 5: Disconnecting Battery Ground (GND) Strap

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Disconnect battery Ground (GND) strap (arrow) with ignition switched off.

WARNING:

Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.

Open cap of coolant expansion tank.
Remove both front wheels.

Fig 6: Identifying Exhaust Pipe Fasteners

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For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of auxiliary heater on sound insulation.

Fig 7: Identifying Quick-Release Fasteners And Noise Insulation

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Remove bolts or quick-release screws -1- and -2- and remove front sound insulation.
Remove quick-release screws -3- and remove rear sound insulation, if present.

Fig 8: Removing Bracket For Noise Insulation

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Remove bracket for sound insulation (arrows).
Remove front bumper:

Refer to

63 BUMPER
63 - BUMPERS for BODY EXTERIOR - CABRIOLET

Place VAG1306 drip tray beneath engine.

Vehicles with drain plug

Fig 9: Identifying Drain Plug

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Turn radiator drain plug -2- counterclockwise, if needed attach accessory hose to connection flange and drain coolant.

Vehicles without drain plug

Remove retaining clamp for Engine Coolant Temperature (ECT) sensor (on radiator) -G83-.
Remove Engine Coolant Temperature (ECT) sensor from outlet and drain coolant.

All

Pull off retaining clip -1- for lower coolant hose and disconnect coolant hose from radiator.

Fig 10: Disconnecting Lower Coolant Hose From Radiator

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Disconnect left coolant hose from radiator (arrow).

Fig 11: Disconnecting Coolant Hose At Oil Cooler

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In addition, disconnect coolant hose at oil cooler (arrow) and drain remaining coolant.
Place oil pan underneath.

Fig 12: Disconnecting Hydraulic Lines To Cooling Coil At Rear Of Bumper

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Disconnect hydraulic lines to cooling coil at rear of bumper (arrows).

Vehicles with automatic transmission

NOTE: Observe the rules of cleanliness for working on automatic transmissions:

Refer to

37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J
37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J - INTERNAL COMPONENTS, SERVICING

Refer to 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

Place oil pan underneath.

Fig 13: Removing Union Nuts And Disconnect ATF Lines

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Remove union nuts -3- and disconnect ATF lines.
Remove bracket for ATF lines, to do so remove nuts -1- and -2-.

All

Fig 14: Removing Cover In Engine Compartment (Right Side)

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Remove cover -1- in engine compartment (right side).

Fig 15: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct

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Remove bolts (arrows).
Detach Evaporative Emission (EVAP) canister purge regulator valve -N80- -1- at air guide.
Remove air guide -2-.

Fig 16: Removing Cover In Engine Compartment (Left Side)

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Remove cover -1- in engine compartment (left side).

Fig 17: Disconnecting Top Coolant Hose From Radiator

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Disconnect top coolant hose -1- from radiator.
Remove electrical harness connector -2- for left and right airbag sensors on bumper.....
....and move cables clear.

Fig 18: Removing Electrical Harness Connectors And From Bracket

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Remove electrical harness connectors -1- and -2- from bracket and disconnect them.

Fig 19: Disconnecting Electrical Harness Connector For Headlights At Both Sides Of Vehicle

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Disconnect electrical harness connector (arrow) for headlights at both sides of vehicle.

Fig 20: Removing Air Ducts On Left/Right Of Radiator

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Remove air guides from left and right of radiator (arrows).

Fig 21: Identifying Outside Air Temperature Sensor G17, Bolts & High Pressure Sensor G65 Electrical Harness Connector

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Unclip temperature sensor -2- for outside temperature display from bracket.
Unscrew bolts -3- and -4- and remove power steering cooling coil.
Disconnect harness connector -1- at High pressure sensor -G65-.

WARNING:

Do not open refrigerant circuit for A/C system.

Remove condenser mounting bolts (arrows).

NOTE: Do not bend or stretch lines or hoses as condenser and/or refrigerant lines/hoses may be damaged.

Carefully swing condenser downward and move aside.

Fig 22: Removing Bolts At Left/Right Side Of Bumper

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Remove bolts (arrows) on left and right sides of bumper.
Unhook hood cable from lock and move cable free.

Fig 23: Unscrewing Bolts At Impact Absorbers At Left/Right

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Unscrew bolts at impact absorbers (arrows) at left and right.

NOTE: A second technician is required to remove the lock carrier.

Remove lock carrier and set aside so it cannot topple.

Fig 24: Removing Rear Engine Cover

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Remove rear engine cover (arrows).

Fig 25: Identifying Holding Plate, Intake Air Hose, Hose & Air Duct

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts for holding plate -3- for solenoid valves (arrows).
Disconnect intake air hose -1- at Mass Air Flow (MAF) sensor.
Remove hose -4- of crankshaft housing ventilation from air duct -2-.

Fig 26: Removing Bolt And Disconnect Air Duct At Throttle Valve Control Module

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Remove bolt (arrow) and disconnect air duct -2- at throttle valve control module.
Disconnect hose -1- from air guide if installed.

NOTE: Illustration depicts air guide with the removed engine from rear.

Fig 27: Removing Coolant Hoses

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Remove coolant hoses -1- and -2-.

NOTE: Coolant hose -3- remains connected.

Remove coolant reservoir (arrow)
Disconnect electrical wiring to Engine Coolant Level (ECL) warning switch -F66- at bottom of expansion tank.

Fig 28: Identifying Ground (GND) & Vacuum Hoses

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Disconnect ground (GND) -2-.
Disconnect vacuum hoses -1- and -3-.

Fig 29: Disconnecting Vacuum Line To Leak Detection Pump At Throttle Valve Control Module

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Disconnect vacuum line (arrow) to leak detection pump at throttle valve control module.

Vehicles with automatic transmission

Fig 30: Disconnecting Electrical Harness Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector (arrow).

All

Place oil pan underneath.

Fig 31: Disconnecting Hose From Power Steering Fluid Reservoir & Vacuum Hose To Vacuum Reservoir

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect hose -1- from power steering fluid reservoir.
Disconnect vacuum hose -2- to vacuum reservoir.

Fig 32: Disconnecting Connector From Secondary Air Injection (AIR) Pump Motor V101 & Hose From Pipe To Secondary Air Combination Valve

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector (lower arrow) at Secondary Air Injection (AIR) pump motor -V101- and move cable free.
Disconnect hose at tube to combination valve for Secondary Air Injection (AIR) (upper arrow).

Vehicles up to 06.03:

WARNING:

Fuel system is under pressure! Before opening system, place rags around the connection. Then release pressure by carefully loosening connection.

Fig 33: Locating Fuel Supply Line And Fuel Return Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect fuel supply line -1- and fuel return line -2- and set aside.

Vehicles as of 07.03:

WARNING:

Fuel system is under pressure! Before opening system, place rags around the connection. Then release pressure by carefully loosening connection.

Fig 34: Unscrewing/Screwing Fuel Hose From Connection On Fuel Rail Pipe

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Unscrew fuel hose from connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head -1- and -3- and unscrew union nut -2-.

All:

Fig 35: Removing Lines/Harness Connectors

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Remove the following lines/harness connectors:

1 - At Evaporative Emission (EVAP) canister purge regulator valve -N80-

2 - Vacuum hose at Evaporative Emission (EVAP) canister purge regulator valve -N80-

3 - at Mass Air Flow (MAF) sensor -G70-

Disconnect hose connections, move wires free and remove air filter housing (arrows).

NOTE: Place a rag under the hydraulic pressure lines, to catch escaping hydraulic fluid.

Fig 36: Unbolting Hydraulic Pressure Line For Power Steering At Rear Coolant Pipe And Disconnecting Line At Height Of Right Cylinder Head

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Unbolt hydraulic pressure line for power steering at rear coolant pipe -1- and disconnect line at height of right cylinder head -2-.

Fig 37: Removing Securing Clips And Cowl

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pry off both covers -3- using a screwdriver.
Loosen hex-nuts -4- by several turns.
Loosen wiper arm -2- by lightly tilting from wiper axle.
Remove hex nuts completely and remove wiper arms.

Disconnect securing clips -1- and remove cowl grill -5-.

Vehicles with automatic transmission

Fig 38: Disconnecting Electrical Harness Connector At Brake Booster Pressure Sensor -G294-

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Disconnect electrical harness connector (arrow) at Brake booster pressure sensor -G294-.

All

Fig 39: Removing Screws And Cover From E-Box In Plenum Chamber

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Remove heater core E-box cover (arrows).

Fig 40: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using a screwdriver, pry off retaining bracket (arrow).

Fig 41: Releasing Connector Latches And Pulling Off Connectors On Engine Control Module

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disengage connector catches (arrows) and disconnect harness connectors -1- and -2- from Engine Control Module (ECM).

Vehicles with automatic transmission 01V

Unclip Transmission Control Module (TCM) retaining bracket.

Fig 42: Disengaging Harness Connector And Disconnecting It From Transmission Control Module (TCM)

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Disengage harness connector (arrow) and disconnect it from Transmission Control Module (TCM).

All

Fig 43: Disconnecting Rear Connectors On Connector Strip & Unbolt Electrical Wire Connection

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Disconnect rear connectors -2- on connector strip and set wiring harness aside.
Unbolt electrical wire connection -1-.

Fig 44: Locating Auxiliary Relay Carrier Catches

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Disengage locking mechanisms (arrows) and remove secondary relay carrier in E-box toward top.
Unhook engine wiring harness at E-box and at bulkhead and move it free.
Remove heat shield for harness connectors at left of bulkhead, if installed.

Fig 45: Removing Harness Connectors From Bracket At Left Of Bulkhead

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Remove harness connectors -1 to 4- from bracket at left of bulkhead.
Disconnect electrical harness connectors -1- and -4-.
Expose oxygen sensor wires.
Remove bracket for harness connectors.

Fig 46: Removing Harness Connectors From Bracket At Right Of Bulkhead

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove harness connectors -1 to 4- from bracket at right of bulkhead.
Disconnect electrical harness connectors -1-, -3- and -4-.
Expose oxygen sensor wires.
Remove bracket for harness connectors.

Fig 47: Removing Nut For Left Exhaust Pipe/Exhaust Manifold

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Remove nut -2- for left exhaust pipe/exhaust manifold which is accessible from top.

NOTE: Illustration is shown with engine removed.

Fig 48: Removing Nut For Right Exhaust Pipe/Exhaust Manifold

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Remove nut -2- for right exhaust pipe/exhaust manifold which is accessible from top.

NOTE: Illustration is shown with engine removed.

Disconnect coolant hoses to heater core at rear coolant pipe and at right coolant pipe. To do so, remove wiring harness screw clip on right side of vehicle.
Remove upper mounting bolts for engine/transmission. One bolt remains tightened by hand.

Fig 49: Removing Front Engine Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove front engine cover (arrows).

NOTE: Before removing ribbed belt, mark direction of rotation with chalk or felt-tip marker. Reversing the direction of rotation of a run-in belt can destroy the belt.

Fig 50: Swinging Ribbed Belt Tensioner To Release Tension On Ribbed Belt Using 3299 Ribbed Belt Installation Tool And 3299/1 Claw For Tensioner

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Swing ribbed belt tensioner in direction of arrow to release tension on ribbed belt using 3299 ribbed belt installation tool and 3299/1 claw for tensioner.
Remove ribbed belt from pulley of power steering pump.
Place engine oil drip tray beneath engine.
Drain engine oil.

Fig 51: Identifying Oil Filter, Coolant Hose & Oil Cooler

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Remove oil filter -2-.
Place VAG1306 drip tray beneath engine.
Remove coolant hose -3- from oil cooler.
Remove oil cooler -1-.

Fig 52: Unbolting Bracket For Refrigerant Line At Oil Pan

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt bracket for refrigerant line at oil pan (arrow).

NOTE: Depicted in illustration for a vehicle with manual transmission.

Fig 53: Disconnecting Harness Connector Of Electrical Wire To A/C Compressor Clutch

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Disconnect harness connector -1- of electrical wire to A/C compressor clutch.

WARNING:

Do not open refrigerant circuit for A/C system.

Unbolt A/C compressor from bracket (arrows).
Hang A/C compressor together with condenser with connected lines at right side of vehicle.
Disconnect electrical lines from generator.

Fig 54: Unscrewing Bolts And Removing Generator

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Unscrew bolts (arrows) and remove generator.

Fig 55: Removing Left/Right Heat Shields For Drive Axles

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove left and right heat shields for drive axles -1-.

Fig 56: Removing Electrical Wires From Starter & Disconnecting Ground (GND) Wire

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove electrical wires -1- and -2- from starter.
Disconnect Ground (GND) wire -3-.

Fig 57: Removing Heat Shield From Solenoid, Unscrewing Bolts & Removing Starter

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove heat shield -1- from solenoid.
Unscrew bolts -2- and -3- and remove starter.

Vehicles with automatic transmission 01V

Fig 58: Torque Converter Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unscrew 3 Torx bolts (arrow) of torque converter in opening of removed starter (turn crankshaft 1/3 rotation in each case).

NOTE: To loosen the torque converter bolts counterhold the main harmonic balancer bolt.

Fig 59: Removing Bolts For Front Vehicle Floor Crossmember

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Remove bolts for front vehicle floor crossmember -1- to -4-.

All

NOTE: Flex joint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged.

Fig 60: Disconnecting Exhaust System At Double Clamps

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Disconnect exhaust system at double clamps (arrows).

Fig 61: Removing Nut For Left Exhaust Pipe/Exhaust Manifold

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove nuts -1- and -3- for front exhaust pipe/left exhaust manifold which are accessible from bottom.

NOTE: Illustration is shown with engine removed.

Pull front exhaust pipe off of left exhaust manifold.

Fig 62: Removing Nut For Right Exhaust Pipe/Exhaust Manifold

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove nuts -1- and -3- for front exhaust pipe/right exhaust manifold which are accessible from bottom.

NOTE: Illustration is shown with engine removed.

Pull front exhaust pipe off of right exhaust manifold.
Where installed, unbolt heat shield for engine speed (RPM) sensor.

Fig 63: Location Of Engine Speed (RPM) Sensor G28 On Coupling Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove Engine Speed (RPM) sensor -G28- on left of transmission (arrow) and lay to side.

Vehicles with manual transmission

Fig 64: Disconnecting Harness Connector For Back-Up Light Switch At Right Of Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect harness connector for back-up light switch at right of transmission and set aside electrical wire.

NOTE: Depicted in illustration for a vehicle with manual transmission 01E all wheel drive.

Fig 65: Disconnecting Harness Connector From Speedometer Vehicle Speed Sensor (VSS) -G22- At Left Of Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect harness connector (arrow) from Speedometer Vehicle Speed Sensor (VSS) -G22- at left of transmission.

NOTE: Depicted in illustration for a vehicle with manual transmission 01E all wheel drive.

Vehicles with automatic transmission 01J

Fig 66: Disengaging Harness Connector From Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disengage harness connector -A- in direction of arrow and disconnect it from transmission.
Move wiring harness clear.

Vehicles with automatic transmission 01V

Fig 67: Identifying Transmission Wiring Harness, Speedometer Vehicle Speed Sensor (VSS) -G22- Harness Connector, Multi-Function Switch Harness Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Swing securing lever and disconnect harness connector for transmission wiring harness -1-.
Disconnect harness connector -2- on Speedometer Vehicle Speed Sensor (VSS) -G22-.
Disconnect harness connector -3- from wire for multi-function switch.

All

Fig 68: Threaded Connections And Positioning Sleeves On Lower Engine Mounts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mark installation positions for threaded assemblies -1- and positioning sleeves -2-.

NOTE: Different mounting holes are available depending upon the installed engine.

Remove lower nuts -1- on left and right engine mounts.

Fig 69: Locating Upper Nuts On Left/Right Engine Mounts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slightly loosen upper nuts (arrow) on left and right engine mounts.

Fig 70: Unbolting Torque Support

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt torque support (arrows).

Fig 71: Locating T10062 Support On Threaded Holes For Torque Support

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten T10062 support on threaded holes for torque support to 20 Nm.
Lift engine using VAG1383A engine/transmission jack just far enough so that lower connecting bolts at engine/transmission can be removed.

NOTE: When working on a vehicle with all wheel drive, make sure the front constant velocity joint of driveshaft is not damaged when lifting engine.

Fig 72: Three Lower Engine And Transmission Connecting Bolts

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Remove bottom engine/transmission connecting bolts (arrows).
Lower engine again.

Vehicles with manual transmission and automatic transmission 01J

Fig 73: Positioning 10-222A Engine Support Bridge On Bolted Flanges Of Fenders Behind Gas-Filled Strut

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position 10-222A engine support bridge on bolted flanges of fenders behind gas-filled strut. Spindle is at front.
Hook 3147 engine support adapter into bolt hole at left of transmission housing.
Connect 3147 engine support adapter and 10222A engine support bridge with 10222A/2 additional hook.

NOTE:

Illustration is shown with engine removed.
If the engine support adapter 3147 can not be inserted far enough into the hole on transmission bell housing due to a change in wire routing, use a long bolt M10 and additional hook 10-222 A/2 in place of engine support adapter.

Vehicles with automatic transmission 01V

Fig 74: Positioning 10-222A Engine Support Bridge On Bolted Flanges Of Fenders Behind Gas-Filled Strut

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position 10-222A engine support bridge on bolted flanges of fenders behind gas-filled strut. Spindle is at front.
Hook 3147 engine support adapter into middle bolt hole in transmission housing.
Connect engine support adapter 3147 using engine support bridge 10-222 A.

NOTE: Illustration is shown with engine removed.

All

Fig 75: Hooking In 2024A Engine Sling At Engine And At VAS6100

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hook in 2024A engine sling at engine and at VAS6100 or 1202A workshop crane as depicted in illustration.

NOTE: To properly balance assembly, mounting hooks must be inserted in rails as shown in illustration.

WARNING:

Take-up hooks and pins at engine sling must be secured using securing pins (arrows) as shown in illustration.

Remove final mounting bolt.

NOTE: Verify that all hoses and lines between engine and body have been disconnected.

Using VAS6100 or VAG1202A workshop crane, lift engine far enough until threaded bolts of engine mount are free.
Turn 10-222A engine support bridge shaft.

NOTE: Make sure no lines are damaged at bulkhead.

Vehicles with automatic transmission 01V

Fig 76: Pressing Transmission Off Engine, While Pressing Torque Converter Off Of Drive Plate

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press transmission off engine, while pressing torque converter off of drive plate.

All

Pull engine off of transmission and lift it out of engine compartment toward front.

Vehicles with automatic transmission 01V

If necessary, secure torque converter in transmission from falling out using wire.

Installing

Installation is reverse of removal, note the following:

NOTE:

During installation, all cable ties must be re-installed at the same locations.
Heat boots, which are removed during engine removal must be reinstalled at the same locations when re-installing engine.
Secure all hose connections using hose clamps appropriate for the model type
Replace self-locking nuts and bolts during assembly work.
Always replace bolts that are secured with tightening torque as well as O-rings and gaskets.

Make sure centering sleeves for engine to transmission are correctly installed in cylinder block. Install or replace if necessary.
Slide intermediate plate or intermediate panel onto sleeves.

Vehicles with manual transmission

Clean input shaft splines and (in case of used clutch plates) clean hub splines. Remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Do not grease guide sleeve.
Check centering of clutch disc.
Check clutch release bearing for wear and replace if necessary.

Fig 77: Servicing Release Bearing With Plastic Ring

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If plastic ring of release bearing is loose, adhere it to bearing ring again using adhesive AMV-195-KD1-01.

3 rectangular tabs (arrows) of plastic ring reach into cutouts of bearing ring.
If grooves with depth of more than 0.5 mm are present, release bearing must be replaced.

Vehicles with SAC clutch pressure plate

When installing a new clutch disc in combination with a used SAC pressure plate (self-adjusting pressure plate), the adjustment ring of the pressure plate must be turned back to impact. Otherwise the pressure plate works with decreased contact pressure (clutch slips).

Refer to 30 CLUTCH

If the clutch disc is not replaced, the adjustment ring does not have to be turned back.

New SAC pressure plates are already pre-adjusted and must not be turned back.

Vehicles with automatic transmission 01V

Fig 78: Bolting Drive Plate To Crankshaft With Centering Bushing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drive plate is bolted to crankshaft with a centering bushing (arrow).
Use original bolts when securing torque converter to drive plate:

Fig 79: Checking Torque Converter Is Correctly Positioned

Courtesy of VOLKSWAGEN UNITED STATES, INC.

When torque converter is installed correctly, distance between lower contact surface of threaded holes at torque converter and contact surface of converter housing on Automatic Transmission 01V is approx. 23 mm.

If the torque converter is not inserted completely, this distance will be approx. 11 mm.

WARNING:

In case of an incorrectly inserted torque converter, the coupling plate of the torque converter or the ATF pump will be destroyed, if the transmission is flanged to the engine.

All

Carefully guide engine with transmission into chassis.
Set engine onto engine mounts.

WARNING:

For vehicles with automatic transmission 01V, keep checking whether the torque converter behind the drive plate can be turned before and during tightening of the bolts at engine/transmission flange. If the torque converter cannot be turned, it must be assumed that it has not been inserted properly and that the coupling plate of the torque converter or the ATF pump will be destroyed during final tightening of the bolts.

Bolt transmission to engine, from. Refer to Tightening torques .

Fig 80: Locating T10062 Support On Threaded Holes For Torque Support

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten T10062 support on threaded holes for torque support to 20 Nm.
Lift engine using VAG1383A engine/transmission jack just far enough so that lower connecting bolts at engine/transmission can be installed.

NOTE: When working on a vehicle with all wheel drive, make sure the front constant velocity joint of the driveshaft is not damaged when lifting the engine.

Fig 81: Three Lower Engine And Transmission Connecting Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten lower engine/transmission connecting bolts (arrows).
Lower engine again.
Install and align exhaust system free of tension. Refer to Exhaust system, aligning free of stress (vehicles with front wheel drive) or Exhaust system, aligning free of stress (vehicles with all wheel drive) .
Install starter.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Install generator. Refer to Ribbed belt for power steering pump, generator and A/C system .
Install A/C compressor. Refer to Ribbed belt for power steering pump, generator and A/C system .
Install ribbed belt. Refer to Installing .
Install lock carrier. Refer to Lock carrier, moving into service position .

Vehicles up to 06.03:

Fig 82: Locating Fuel Supply Line And Fuel Return Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten union nut of fuel supply line -1- to 22 Nm.
Secure fuel return line -2- with a hose clamp.

Vehicles as of 07.03:

Fig 83: Unscrewing/Screwing Fuel Hose From Connection On Fuel Rail Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure fuel hose to connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head -1- and -3- and tighten union nut -2- to 22 Nm.

Vehicles with automatic transmission

Secure ATF lines:

Refer to

37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J
37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J - INTERNAL COMPONENTS, SERVICING

Refer to 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

All

Check harness connectors and routing:

Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations

See Caution for connecting Telematics battery. Refer to Engine, removing and installing

Observe safety precautions after connecting battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

WARNING:

Do not use a battery charger for starting assistance! There is risk of damage at the vehicle control modules.

Check engine oil level before starting engine.
Top off coolant. Refer to Filling .

NOTE:

Only reuse drained coolant if cylinder head or engine block were not replaced.
Dirty coolant cannot be reused.

Fill up power steering fluid and bleed steering system:

Refer to 48 - STEERING

Vehicles with automatic transmission

Check ATF level:

Refer to

37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J
37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J - INTERNAL COMPONENTS, SERVICING

Refer to 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

All

Adjust headlights:

Refer to 94 LIGHTS, SWITCHES - EXTERIOR .