Engine, Installing

WARNING: This page is about a different car, the 2008 Volkswagen Jetta, 2008 Volkswagen GLI, 2007 Volkswagen Jetta, and 2006 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Installation is performed in reverse order. When doing this 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 (for example: fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake or vacuum) and electrical wires so that the original path is followed.
To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

NOTE:

Installing the engine/transmission bolts. Refer to one of the following:

Manual transmission, refer to INSTALLING

DSG transmission , refer to DSG TRANSMISSION MECHATRONIC -J743-, TRANSMISSION REMOVED .

During the installation, all cable ties must be reinstalled in the same location.

Secure all hose connections with hose clamps.

During assembly, replace the self locking nuts and bolts.

Always replace bolts that have been tightened to specification as well as O-rings and seals.

Electrical connections and routing. Refer to WIRING HARNESS AND CONNECTOR REPAIRS .

-- Insert new alignment pins for centering the engine/transmission.

-- Engage the intermediate plate at the sealing flange and slide it onto the alignment pins -arrows-.

Fig 1: Identifying Intermediate Plate Alignment Bushings

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

With a Manual Transmission

-- Check the clutch release bearing for wear and replace, as necessary.

-- Grease the splines of the input shaft lightly with grease G 000 100.

-- Check and install the clutch and clutch mechanism. Refer to CLUTCH .

Continuation for All Vehicles

-- When installing the engine/transmission assembly, ensure there is clearance to the subframe, turbocharger and Air Conditioning (A/C) compressor.

-- Align the engine mount free of tension by using a shaking motion, also loosen the engine mount to the longitudinal member if necessary.

NOTE:

Checking and adjusting the engine and transmission mounts. refer to the following:

Checking, refer to ENGINE MOUNT ADJUSTMENT, CHECKING .

Adjusting, refer to ENGINE AND TRANSMISSION MOUNT, ADJUSTING .

Engine and transmission mount tightening specifications. Refer to FASTENER TIGHTENING SPECIFICATIONS .

-- Install the pendulum support. Refer to FASTENER TIGHTENING SPECIFICATIONS .

-- Install the front exhaust pipe. Refer to CATALYTIC CONVERTER WITH FRONT EXHAUST PIPE .

-- Install the drive axles. Refer to Removal and Installation

With a Manual Transmission

-- Install the shift mechanism and adjust, if necessary. Refer to SHIFT MECHANISM .

-- Install the hose/pipe assembly to the slave cylinder, see the transmission installing procedure in INSTALLING .

With a DSG Transmission

-- Install and adjust the selector lever cable. Refer to SELECTOR LEVER CABLE, THROUGH 02.09 .

-- Install the A/C compressor to the accessory bracket. Refer to REMOVAL and Installation .

-- Install the ribbed belt. Refer to RIBBED BELT .

Continuation for All Vehicles

-- Install the plenum chamber bulkhead. Refer to DESCRIPTION AND OPERATION .

-- Route the engine wiring harness to the control module -1- beneath and to the left (in direction of vehicle travel) of the wiring harness -2-.

Fig 2: Routing/Removing Engine Wiring Harness To Control Module Beneath And At Left (In Direction Of Travel) Of Wiring Harness

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the battery holder and tighten the bolts -arrows-.

Fig 3: Identifying Cover Of E-Box, Wire & Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Route the wire -2- as shown in the illustration and tighten it to the E-box -1-.

-- Install the battery and follow the necessary measures after connecting the battery. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] Removal and Installation .

-- Fill the cooling system. Refer to DRAINING AND FILLING .

-- Connect the vehicle diagnosis, testing and information system VAS 5051 B, VAS 5052 or VAS 5053.

-- Check all Diagnostic Trouble Code (DTC) memories and erase all DTC entries that resulted from removing and installing the engine.

NOTE:

If the DTC memory was erased, generate a readiness code. Refer to "Guided Function".

-- Perform a test drive.

-- Then perform the vehicle system test and repair any occurring malfunctions.

Tightening Specifications

Bolted connections		Nm
Bolts and Nuts	M6	10
	M7	15
	M8	25
	M10	40
	M12	60
Engine/transmission bolts, refer to one of the following: Manual transmission, refer to SPECIFICATIONS . DSG transmission, refer to SPECIFICATIONS .
Engine and transmission mount tightening specifications. Refer to FASTENER TIGHTENING SPECIFICATIONS .