Engine, Installing

WARNING: This page is about a different car, the 2006 Volkswagen Jetta and 2005 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 (e.g. for fuel, hydraulic, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
Ensure sufficient clearance to all moving or hot components.

NOTE:

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

Secure all hose connections with hose clamps.

During assembly, replace self-locking nuts and bolts.

Always replace bolts that are tightened to torque as well as O-rings and gaskets.

-- Insert new centering sleeves for centering engine/transmission in cylinder block.

-- Make sure that the intermediate plate is hooked in at the sealing flange and is pushed onto the alignment sleeves -arrows-.

Fig 1: Identifying Intermediate Plate Is Hooked In At Sealing Flange And Is Pushed Onto Alignment Sleeves

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Align engine mount free of tension by using shaking motions, also loosen engine mount at chassis if necessary.

NOTE:

Checking and adjusting subframe mount DIAGNOSIS AND TESTING .

Tightening specifications of subframe mount ENGINE AND TRANSMISSION MOUNT TIGHTENING SPECIFICATIONS .

Connecting bolts of engine/transmission:

Automatic Transmission: [For transmission(s) 02E] Removal and Installation

Manual Transmission: [For transmission(s) 0A4] Removal and Installation

Electrical connections and routing [For transmission(s) 0A4, 02E, 09G, 02Q] Wiring and Wiring .

-- Install pendulum support ENGINE AND TRANSMISSION MOUNT TIGHTENING SPECIFICATIONS .

-- Install the drive axles Removal and Installation .

-- Install front exhaust pipe EXHAUST SYSTEM ASSEMBLY OVERVIEW .

With Manual Transmission

-- Install the hydraulic clutch slave cylinder [For transmission(s) 0A4] SLAVE CYLINDER ,

-- Remove the shift mechanism to the transmission [For transmission(s) 0A4] SHIFT MECHANISM .

With DGS

-- Install the selector lever cable to the transmission, refer to [For transmission(s) 02E] SHIFT MECHANISM .

Continuation for All

-- Install the generator [For transmission(s) 0A4, 02E, 09G, 02Q] Removal and Installation .

-- Install A/C compressor Removal and Installation .

-- Install ribbed belt RIBBED DRIVE BELT .

-- Install noise insulation Removal and Installation .

-- Install Engine Control Module (ECM) REMOVAL AND INSTALLATION .

-- First install battery holder and tighten bolts -arrows-.

Fig 2: Identifying Cover Of E-Box, Wire & Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Route wire -2- as depicted in the illustration and bolt it tightly on to E-box -1-.

-- Install plenum chamber bulkhead Description and Operation .

-- Install battery [For transmission(s) 0A4, 02E, 09G, 02Q] Removal and Installation .

-- Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .

-- Adapt the engine control module, use "Guided Functions".

-- Perform vehicle system test, use "Guided Fault Finding".

-- Then, end "Guided Fault Finding".

Observe safety precautions that apply to road tests.

-- Perform test drive.

-- After that perform vehicle system test anew and repair any occurring malfunctions.

Tightening Specifications

Bolted connections		Tightening Specifications
Bolts and Nuts	M 6	10 Nm
	M 8	20 Nm
	M10	45 Nm
	M12	60 Nm