Engine, installing

NOTE: When performing repairs, always replace seals and gaskets as well as self-locking nuts and bolts which have a specified tightening torque.

Installation is performed in the reverse order. Note the following:

Check whether dowel sleeves for centralizing engine/transmission are in cylinder block and install if necessary.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engage intermediate plate on sealing flange, and press onto dowel sleeves (arrows).

Make sure that clutch plate is properly centered.

Check clutch release bearing for wear. Replace if necessary.
Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with G 000 100.
Install slave cylinder for hydraulic clutch release mechanism:

Refer to

30 CLUTCH for 5 AND 6 SPD. MANUAL TRANSMISSION 02M, 02Y ALL WHEEL DRIVE
30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 02J FRONT WHEEL DRIVE

Fig 2: Identifying Engine Supports Bolts & Distance Between Engine Console & Support Arm

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Adjust engine mounting so that distance -a- (on right side mounting) is about 13 mm. It should be possible to insert a 12 mm flat metal bar (e.g. special tool 2011) without any difficulty.
To move engine within engine console, first loosen bolts -b- on left and right engine supports by about 2 turns each.

Adjusting engine mounting. Refer to Engine mountings, adjusting .

Attach selector cables to transmission and adjust:

Refer to

34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 AND 6 SPD. MANUAL TRANSMISSION 02M, 02Y ALL WHEEL DRIVE
34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 02J FRONT WHEEL DRIVE

Install power steering pump:

Refer to 48 STEERING

Installing drive axle

Insert drive axle.
Insert outer CV joint as far as possible.
Lower vehicle making sure wheels do not touch ground.

NOTE: Wheel bearings can be damaged.

Depress brake pedal (second technician needed).
Tighten 12-point nut.

NOTE: Tightening torques for 12-point nuts vary.

Refer to 40 FRONT SUSPENSION

Vehicles with air conditioning

Fig 3: Unbolting A/C Compressor & Pressing Sliding Bushing Back Into Hole

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To facilitate installing air conditioning compressor, knock back threaded bushes -B- for mounting bolts -A- slightly in direction indicated (arrow).

All vehicles

Install ribbed belt. Refer to Installing ribbed belt .
Install front exhaust pipe. Refer to Front exhaust pipe, removing and installing .

NOTE: Avoid excessive bending of the de-coupling element (no more than 10°).

Stress-free alignment of exhaust system. Refer to Exhaust system, aligning stress-free .

Connect coolant hoses. Refer to Engine cooling system components, overview .
Connect vacuum hoses. Refer to Charge air pressure control system and vacuum system connections, diagram .
Fill up with coolant. Refer to Filling .

NOTE:

Drained-off coolant may only be used again if the original cylinder head and cylinder block are re-installed.
Do not use coolant that is dirty or contaminated.

Check oil level before starting engine. Refer to Engine oil level, checking .

Electrical connections and routing:

Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations

After connecting battery terminals, enter anti-theft code for radio.

Refer to Radio operating instructions

CAUTION:

If a battery charger is used to give the engine an assisted start, there is a risk that the control modules in the vehicle will be damaged.

Close power windows in front doors to their top positions using electric switches.
Operate all power window switches again for at least one second in "close" direction to activate automatic one-touch function.
Set clock to correct time.
Perform adaptation of throttle valve control module.

Refer to

24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMU
24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): ATC
24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWP
24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): BEA

Check DTC memory.

Refer to

01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMU
01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): ATC
01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWP
01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): BEA

NOTE: DTCs will be stored in the memory because connectors have been disconnected. Therefore, check and erase DTC memory after installing the engine.