Engine, Installing

Procedure

Secure the engine/transmission assembly to the : T10497A .

-- Replace the bolts that were tightened with an additional turn.

-- Replace the self-locking nuts and bolts, gaskets, seals and O-rings.

-- Bring all cable ties back to the same position.

-- Install the intermediate plate. Refer to Fig 1.

Fig 1: Identifying Intermediate Plate

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-- If the alignment sleeves -A- for centering the engine and transmission are missing inside the cylinder block, then install the alignment sleeves.

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-- Tighten the transmission to the engine at positions -1, 2, 3, 6, 7, 8, 9-.

-- Install the transmission support.

-- Lift the engine/transmission assembly using the T10497A.

-- Guide the engine/transmission assembly into the body.

-- Install the bolts -arrows- for the engine mount by hand all the way.

Fig 2: Identifying Engine Mount Bracket Bolts

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-- Install the bolts -arrows- for the transmission mount by hand until it is in position.

Fig 3: Identifying Bolts

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NOTE:

The bolts are only tightened to the final tightening specification after the subframe mounts have been adjusted. Refer to ASSEMBLY MOUNT, ADJUSTING .

-- Remove the : T10497A from the engine.

-- Install the starter. Refer to STARTER, REMOVING AND INSTALLING .

-- Install the air duct pipe. Refer to OVERVIEW - CHARGE AIR SYSTEM .

-- Install the air ducts. Refer to Fig 4.

Fig 4: Air Guide Hose Clamps Sizes

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Vehicles with Manual Transmission

-- Install the clutch slave cylinder. Refer to CLUTCH SLAVE CYLINDER, REMOVING AND INSTALLING (02S) .

-- Install the cables with the cable bracket. Refer to OVERVIEW - SELECTOR MECHANISM (09S) or OVERVIEW - SHIFT MECHANISM (02S) .

Vehicles with DSG ^® Transmission

-- Install the selector lever cable, connect the Mechatronic connector and attach all brackets to the transmission. Refer to [For transmission(s) 0GC] Transmission, Removing and Installing , [For transmission(s) 02S] Transmission, Removing and Installing or [For transmission(s) 02Q] Transmission, Removing and Installing

Continuation for All Vehicles

-- Install the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Install the drive axles. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Install the transverse link, ball joint and coupling rod. Refer to OVERVIEW - LOWER CONTROL ARM AND BALL JOINT .

-- Install the A/C compressor. Refer to A/C COMPRESSOR, REMOVING AND INSTALLING FROM BRACKET .

-- Install the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Reconnect the connections and route the wires. Refer to COMPONENT LOCATION OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES and the appropriate Wiring Diagram.

-- Install the Engine/Motor Control Module -J623-. Refer to ENGINE/MOTOR CONTROL MODULE .

-- Connect the coolant hoses with the connector coupling. Refer to Fig 5.

Fig 5: Connecting Coolant Hose Coupling

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-- Install the pendulum support. Refer to PENDULUM SUPPORT, REMOVING AND INSTALLING .

-- Install the left and right front wheel housing liners. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Mount the front wheels. Refer to WHEEL, CHANGING .

-- Adjust the assembly mount. Refer to ASSEMBLY MOUNT, ADJUSTING .

-- Install the battery tray. Refer to BATTERY TRAY, REMOVING AND INSTALLING .

-- Install the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

NOTE:

Do not reuse coolant that has been drained.

-- Fill with coolant. Refer to Filling .

Tightening Specifications

Refer to OVERVIEW - ASSEMBLY MOUNTS
Securing the transmission mounting to engine. Refer to TRANSMISSION, REMOVING AND INSTALLING (02S) or TRANSMISSION, REMOVING AND INSTALLING (09S) .