Engine, installing

Install in reverse order, paying attention to the following:

• Check whether dowel sleeves for centering engine/transmission in cylinder block have been installed and install if necessary.
• Push intermediate plate onto dowel sleeves.

Vehicles with manual transmission 

• Check clutch release bearing for wear and replace if necessary.
• Lightly grease splines on transmission input shaft with G 000 100. Do not grease guide sleeve for release bearing.
• If necessary check that clutch plate is properly centered.
• A needle bearing must be installed in crankshaft on vehicles with manual transmission. Install needle bearing if necessary → Pilot needle bearing in crankshaft, extracting and driving .

Vehicles with automatic transmission 

• On vehicles with automatic transmission, no needle bearing must be installed in crankshaft. Remove needle bearing if necessary → Pilot needle bearing in crankshaft, extracting and driving .
• To secure torque converter on drive plate, only use correct bolts
• Tighten torque converter bolts with Matra V175 15 mm A/F socket attachment.

Checking position of torque converter 

Fig 1: Checking Torque Converter Is Correctly Positioned

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If the torque converter has been correctly installed, the distance between bottom contact surfaces at threaded holes in torque converter and joint surface on torque converter bell housing with automatic transmission 01V, is approx. 23 mm.

If torque converter has not been completely inserted, this distance will be approx. 11 mm.

All models 

• Ensure that engine mounts are installed free of mechanical stress. To do so, shake engine to align it before tightening engine mounts.
• Install air conditioning compressor.
• Install ribbed belt.

Vehicles with automatic transmission 

• Secure ATF lines: →
  • 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V
  • 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING
  • 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE

Stress-free alignment of exhaust system → Exhaust system - vehicles with front wheel drive, aligning stress-free .

Vehicles up to 06.03 

Fig 2: Disconnecting Fuel Supply Line And Set Aside

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Tighten union nut of fuel supply line - 1  - to 22 Nm.

Vehicles as of 07.03 

Fig 3: Counterholding Using An Open-End Wrench At Each Hex Head & Unscrew Union Nut

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Secure fuel hose to connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head - 1  - and - 3  - and tighten union nut - 2  - to 22 Nm.

All 

Electrical connections and routing:

→ Electrical Wiring Diagrams, Troubleshooting and Component Locations

See Caution for connecting Telematics battery → Engine, removing and installing 

• After connecting battery, enter radio anti-theft code. Radio operating instructions.
• Use electric window lifters to completely close door windows.
• Then actuate all window lifter switches again for at least 1 second in "close" position to activate automatic one-touch function.
• Set clock to correct time.

• Check oil level before starting engine.
• Fill cooling system → Cooling system, draining and filling .

• Perform adaptation of throttle valve control module: → 24 - MULTIPORT FUEL INJECTION (MFI)
• Check Diagnostic Trouble Code (DTC) memory:

Vehicles with automatic transmission 

• Check ATF level: →
  • 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V
  • 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING
  • 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE

All models 

• Adjust headlights: → 94 LIGHTS, SWITCHES - EXTERIOR