Engine, installing

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Installation is performed in reverse sequence. Note the following:

CAUTION:

When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:

Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
Ensure sufficient clearance to all moving or hot components.

Insert new dowel sleeves in cylinder block for centralizing engine and transmission.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install intermediate plate onto sealing flange and slide onto dowel sleeves (arrows).

Vehicles with manual transmission

Lightly grease input shaft splines with G 000 100 grease.
Install hydraulic clutch slave cylinder:
Refer to CLUTCH CONTROL, SERVICING

Check clutch and clutch operating mechanism, then install.
Refer to CLUTCH CONTROL, SERVICING

Install gear shift mechanism, adjust gear shift cables if necessary:
Refer to GEAR SELECTOR MECHANISM UP TO 05.99, SERVICING or GEAR SELECTOR MECHANISM FROM 05.99, SERVICING

Vehicles with automatic transmission

Install selector cable on transmission, adjust if necessary:
Refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING

NOTE: Always replace selector cable circlip

Vehicles with air conditioning

Install air conditioner compressor:
Refer to A/C COMPRESSOR AND BRACKET

Observe additional information and installation instructions. Refer to Additional information and assembly work on models with an air conditioning system .

Continued for all vehicles

When installing engine/transmission assembly, ensure sufficient clearance to engine and transmission mountings and radiator.
Align assembly mountings for engine and transmission. Refer to Engine and transmission mountings, aligning .

NOTE: Assembly mounting tightening torques. Refer to Assembly mounting .

Install right axle shaft and attach left axle shaft to transmission:
Refer to FRONT DRIVE SHAFTS, SERVICING

Install front exhaust pipe. Refer to Exhaust system components, removing and installing , Exhaust system components, removing and installing.
Install power steering pump:

Refer to POWER STEERING PUMP WITH HYDRAULIC LINES/HOSES, OVERVIEW

Route wiring harness and connect all electrical connections to engine
Refer to 97 WIRING

Install poly V-belt. Refer to Poly V-belt, removing and installing .
Install sound insulation at left and right sides:
BODY, FRONT

Refill with coolant. Refer to Cooling system, draining and filling .
Vehicles with secondary air injection pump, install pump with bracket.
Adapt (match) engine control module to throttle valve control module. Refer to Adapting components and functions , Adapting components and functions.

Vehicles without Electronic Power Control (EPC)

Adjust throttle cable. Refer to Accelerator mechanism, servicing .

Continued for all vehicles

Test drive vehicle and check Diagnostic Trouble Code (DTC) memory.
Generate readiness code again if DTC memory has been erased or engine control module was disconnected from permanent positive. Refer to Adapting components and functions , Adapting components and functions.