Engine, Installing

WARNING: This page is about a different car, the 2009 Volkswagen GTI and 2008 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.

Installation is performed in the reverse order of removal, noting the following:

CAUTION:

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Route all lines and wires in their original locations.
Ensure sufficient clearance to all moving or hot components.

-- Insert new alignment sleeves in the cylinder block for centering the engine and transmission.

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

Fig 1: Identifying Intermediate Plate Alignment Bushings

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Vehicles with a Manual Transmission

-- Grease the input shaft splines lightly with grease for clutch plate splines -G 000 100-.

-- Inspect and install the clutch and clutch mechanism. Refer to REMOVAL AND INSTALLATION .

Vehicles with a Direct Shift Gearbox (DSG R)

-- Replace the crankshaft needle bearings. Refer to CRANKSHAFT NEEDLE BEARINGS .

-- Install the selector lever cable. Adjust after installing. Refer to SELECTOR LEVER HANDLE .

Continuation for all Vehicles

-- When installing the engine and transmission make sure there is enough clearance to the subframe and radiator. Adjust the engine and transmission mounts. Refer to one of the following:

Passat and CC, refer to .
GTI and Eos, refer to ENGINE AND TRANSMISSION MOUNT, ADJUSTING .
Tiguan, refer to .

NOTE:

For the engine and transmission mount tightening specifications, refer to SPECIFICATIONS .

Electrical connections and routing. Refer to WIRING HARNESSES, REPAIRING .

-- Connect the vehicle diagnostic tester.

-- Check all Diagnostic Trouble Code (DTC) memories and erase all DTC entries which may have occurred during the assembly.

-- Perform a test drive.

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

NOTE:

If the DTC memory was erased, the readiness code must be generated again, refer to "Guided Fault Finding" in the vehicle diagnostic tester.

Tightening Specifications

Bolted Connections		Tightening Specifications
Bolts and Nuts	M6	10 Nm
	M7	15 Nm
	M8	25 Nm
	M10	40 Nm
	M12	60 Nm