Notes on installing

WARNING: This page does not describe the selected car, but rather 15 other vehicles, including the 2006 Volkswagen GTI, 2005 Volkswagen Jetta, 2005 Volkswagen GTI, 2004 Volkswagen Jetta, and 2004 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.

Installation is in reverse of removal, note the following:

CAUTION: 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, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
To prevent damages to the lines, make sure there is sufficient clearance to all moving or hot components.

Make sure alignment sleeves for engine to transmission are installed in cylinder block. Install if necessary.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Vehicles with manual transmission:

If necessary, check centering of clutch drive plate.
Check clutch release bearing for wear and replace if necessary.
Lightly grease clutch release bearing, guide sleeve for release bearing and input shaft splines with Grease G 000 100 . (Part numbers are for reference only. Always check with your Parts Department for the latest part number information).
Install hydraulic clutch slave cylinder, refer to 30 CLUTCH in appropriate MANUAL TRANSMISSION article .

Install shift mechanism, refer to GEAR SELECTOR MECHANISM, SERVICING for 5 & 6 SPD. MANUAL TRANSMISSION 02M or GEAR SELECTOR MECHANISM UP TO 05.99, SERVICING or GEAR SELECTOR MECHANISM FROM 05.99, SERVICING for 5 SPD. MANUAL TRANSMISSION 02J .
If necessary, adjust selector lever cable, refer to INSTALLATION POSITION OF GEAR SELECTOR MECHANISM for 5 & 6 SPD. MANUAL TRANSMISSION 02M or GEAR SELECTOR MECHANISM UP TO 05.99, SERVICING or GEAR SELECTOR MECHANISM FROM 05.99, SERVICING for 5 SPD. MANUAL TRANSMISSION 02J .

Vehicles with automatic transmission 01M

To secure torque converter to drive plate, only use nuts approved by replacement parts program.
Install selector lever cable on transmission, adjust if necessary, refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING for 4 SPD. AUTOMATIC TRANSMISSION 01M or SELECTOR LEVER CABLE, REMOVING AND INSTALLING for 5 SPD. AUTOMATIC TRANSMISSION 09A ON BOARD DIAGNOSTIC (OBD) .
Adapt automatic transmission control module1.

Vehicles with automatic transmission 09A

To secure torque converter to drive plate, only use nuts approved by replacement parts program.
Install selector lever cable on transmission, adjust if necessary, refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING for 4 SPD. AUTOMATIC TRANSMISSION 01M or SELECTOR LEVER CABLE, REMOVING AND INSTALLING for 5 SPD. AUTOMATIC TRANSMISSION 09A ON BOARD DIAGNOSTIC (OBD) .
Adapt automatic transmission control module.

Continuation for all vehicles

When installing assembly, ensure clearance to drive axles.
Align engine and transmission mountings, refer to Engine and transmission mountings, aligning .
Install drive axles, refer to FRONT SUSPENSION, SERVICING or FRONT SUSPENSION (R32), SERVICING .
Install front exhaust pipe refer to Exhaust system components .

Position intake hose (between charge air cooler and Throttle Valve Control Module J338 ) at Throttle Valve Control Module J338 and secure.
Install power steering pump, refer to P.A.S. POWER STEERING PUMP, VEHICLES WITH LOW MOUNTED POWER STEERING PUMP, REMOVING AND INSTALLING or P.A.S. POWER STEERING PUMP, VEHICLES WITH HIGH MOUNTED POWER STEERING PUMP, REMOVING AND INSTALLING .
Electrical connections and routing, refer to 97 WIRING in ELECTRICAL EQUIPMENT and 97 - WIRING in ELECTRICAL EQUIPMENT - GENERAL INFORMATION .
Install ribbed belt, refer to Ribbed belt, removing and installing under Ribbed belt, removing and installing .

Install connecting hoses between Secondary Air Injection (AIR) pump/combination valve and Secondary Air Injection (AIR) pump/air filter.
Install sound insulation tray, refer to NOISE INSULATION (GASOLINE ENGINES), ASSEMBLY OVERVIEW or NOISE INSULATION (DIESEL ENGINES), ASSEMBLY OVERVIEW .
Fill with coolant, refer to Cooling system, draining and filling under Cooling system, draining and filling .
Perform "Procedure after interrupting voltage supply", refer to PROCEDURE AFTER VOLTAGE SUPPLY OPEN CIRCUIT .

Torque specifications:

Bolted connections		Torque specifications
Bolts, nuts	M6	10 Nm
	M7	15 Nm
	M8	25 Nm
	M10	40 Nm
	M 12	60 Nm
Deviation from
Connecting bolts, engine to transmission	M10	45 Nm
Connecting bolts, engine to transmission	M12	80 Nm
Converter to drive plate		60 Nm
Drive axle to drive flange/transmission		40 Nm

NOTE:

Tightening torques of subframe mount, refer to Assembly mounting .