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2.0l - Engine Assembly - Engine Code(s): Aeg, Avh, BDC, Bev & Bgd (hatchback) Volkswagen New Beetle A4

Mechanical 17 illustrations ~2059 words

ENGINE AND TRANSMISSION MOUNT, ALIGNMENT SPECIFICATIONS

WARNINGBefore loosening bolts, secure assembly using engine support bridge 10-222 A.

Engine Mount

Scheme 148

Scheme 148
Scheme 148

a - = 14.0 mm

b- = minimum 10.0 mm

Both bolt heads -1- must be flush with edge -c-.

Transmission Mount

Scheme 149

Scheme 149
Scheme 149

Edges -a- and -b- must be parallel to each other.

c- = 18 to 20 mm

Note. Tightening specifications of engine and transmission mounts ENGINE AND TRANSMISSION MOUNT TIGHTENING SPECIFICATIONS .

FASTENER TIGHTENING SPECIFICATIONS

Bolted connectionsTightening Specifications
Bolts and NutsM 610 Nm
M 715 Nm
M 825 Nm
M1040 Nm
M1260 Nm
Deviation from
Engine to transmission bolts, refer to [For transmission(s) 02E] FASTENER TIGHTENING SPECIFICATIONS , or refer to [For transmission(s) 02J] TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS , or refer to [For transmission(s) 0A4] FASTENER TIGHTENING SPECIFICATIONS , or refer to [For transmission(s) 02M] FASTENER TIGHTENING SPECIFICATIONS [For transmission(s) 09G] FASTENER TIGHTENING SPECIFICATIONS or refer to [For transmission(s) 01M] FASTENER TIGHTENING SPECIFICATIONS
Converter to drive plate, refer to [For transmission(s) 09G] FASTENER TIGHTENING SPECIFICATIONS or refer to [For transmission(s) 01M] FASTENER TIGHTENING SPECIFICATIONS
Starter to transmission Removal and Installation
Install drive axle Removal and Installation

Note. Tightening specifications of engine and transmission mounts ENGINE AND TRANSMISSION MOUNT TIGHTENING SPECIFICATIONS .

ENGINE AND TRANSMISSION MOUNT TIGHTENING SPECIFICATIONS

Engine Mount

Scheme 150

Scheme 150: ENGINE AND TRANSMISSION MOUNT TIGHTENING SPECIFICATIONS
Scheme 150: ENGINE AND TRANSMISSION MOUNT TIGHTENING SPECIFICATIONS
1Mount to body (1)40 Nm + 90° ( 1 / 4 turn)
2Mount/bracket to body25 Nm
3Mount to engine bracket100 Nm
(1) Replace bolts
(1)Replace bolts

Transmission Mount

Scheme 151

Scheme 151
Scheme 151
1Mount to body (1)40 Nm + 90° ( 1 / 4 turn)
2Mounting to body25 Nm
3Mounting to transmission console100 Nm
(1) Replace bolts
(1)Replace bolts

Pendulum Support

Scheme 152

Scheme 152
Scheme 152
1Pendulum support to transmission (1)40 Nm + 90° ( 1 / 4 turn)
2Pendulum support to transmission (1)40 Nm + 90° ( 1 / 4 turn)
3Pendulum support to subframe (1)20 Nm + 90° ( 1 / 4 turn)
(1) Replace bolts
(1)Replace bolts

ENGINE, REMOVING

Special tools and workshop equipment required

  1. Lifting tackle 2024 A
  2. Engine mount T10012
  3. Holding fixture VW 313
  4. Engine and transmission holder VW 540
  5. Shop crane V.A.G 1202 A
  6. Drip tray V.A.G 1306
  7. Torque wrench V.A.G 1331
  8. Torque wrench V.A.G 1332
  9. Engine/transmission jack V.A.G 1383 A
  10. Pliers for spring type clips VAS 5024
  11. Spacers VW 540/1 B
  12. Step ladder VAS 5085
  13. Grease (vehicles with manual transmission) G 000 100
  14. Bolt M10 x 25 / 8.8
  15. Nut M10
  16. Cable tie

The engine is removed downward together with the transmission.

CAUTIONWhen 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, EVAP canister system, 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.

All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.

First, check whether a coded radio is installed. If necessary, obtain the anti-theft coding.

Disconnect battery ground (GND) strap with the ignition switched off.

Remove engine cover.

Remove the power steering reservoir from the battery tray; be sure not to loosen the hoses.

Tie the reservoir to the lock carrier.

Remove the battery and the battery tray Removal and Installation .

WARNINGFuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.

Engine codes AEG, AVH, AZG and BDC

Disconnect the fuel supply line -1- and the fuel return line -2- from the fuel distributor.

Scheme 153

Scheme 153
Scheme 153

Engine codes BEV and BGD

Disconnect the fuel supply line at the connection -1-. To do this, push the securing ring -2- in the connection fitting -3-.

Scheme 154

Scheme 154
Scheme 154

Continuation for All

Seal the lines so that the fuel system is not contaminated by dirt etc.

Remove air filter AIR FILTER ASSEMBLY OVERVIEW .

Remove upper part of intake manifold

  1. Engine code AEG «UPPER INTAKE MANIFOLD ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-1997-2005/remont/fuel-system/#20l-fuel-injection-system-engine-codes-aeg-avh-azg-bdc-bev-bgd-hatchback) .
  2. Engine codes AVH, AZG and BEV «UPPER INTAKE MANIFOLD ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-1997-2005/remont/fuel-system/#20l-fuel-injection-system-engine-codes-aeg-avh-azg-bdc-bev-bgd-hatchback) .
  3. Engine codes BDC and BDG «UPPER INTAKE MANIFOLD ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-1997-2005/remont/fuel-system/#20l-fuel-injection-system-engine-codes-aeg-avh-azg-bdc-bev-bgd-hatchback) .

Note. Seal the intake channels in lower part of intake manifold using a clean cloth.

With Manual Transmission

Remove the shift mechanism from the transmission, refer to [For transmission(s) 02E] SHIFT MECHANISM , or refer to [For transmission(s) 02J] Removal and Installation , or refer to [For transmission(s) 0A4] SHIFT MECHANISM , or refer to [For transmission(s) 02M] GEAR SELECTOR MECHANISM

Remove the hydraulic clutch slave cylinder, refer to [For transmission(s) 02J] HYDRAULIC SYSTEM ASSEMBLY OVERVIEW , or refer to [For transmission(s) 0A4] HYDRAULIC SYSTEM ASSEMBLY OVERVIEW , or refer to [For transmission(s) 02M] CLUTCH SLAVE CYLINDER .

Note. Clutch pedal must not be operated.

With Automatic Transmission 01M

Remove the selector lever cable from the transmission, refer to [For transmission(s) 01M] Removal and Installation .

With Automatic Transmission 09G

Remove selector lever cable from the transmission, refer to [For transmission(s) 09G] SELECTOR LEVER CABLE .

Continuation for All

Remove the center, left and right noise insulation Description and Operation .

Remove ribbed belt RIBBED BELT .

If equipped, remove the auxiliary fan on the right side of the vehicle.

Remove the mounting clamps for the power steering pressure line from the engine and transmission.

Disconnect the power steering pump on the bracket and tie it to the front piece; the hoses remain connected Description and Operation .

Vehicles with Air Conditioning

WARNINGThe air conditioning refrigerant circuit must not be opened.

Note. The refrigerant circuit must only be opened in workshops with trained personnel and the necessary range of tools and workshop equipment. To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

To facilitate removal and installation of the engine without having to open the refrigerant circuit

Remove and install the refrigerant line retaining clamp(s).

Air conditioning compressor, removing and installing Description and Operation .

Secure A/C compressor to body so that the refrigerant lines/hoses are not burdened.

Scheme 155

Scheme 155
Scheme 155

Note. Shield bumper from damage using adhesive tape.

Continuation for All

Disconnect the intake hose and the coolant and vacuum hoses from the engine.

Remove the bracket with the secondary air injection (AIR) pump motor

  1. Engine code AEG through 05.99 «SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-1997-2005/remont/auxiliary-emission-control-systems/#20l-exhaust-system-emission-controls-engine-codes-aeg-avh-azg-bdc-bev-bgd-hatchback) .
  2. Engine codes AVH, AZG, BEV and AEG from 06.99 «SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-1997-2005/remont/auxiliary-emission-control-systems/#20l-exhaust-system-emission-controls-engine-codes-aeg-avh-azg-bdc-bev-bgd-hatchback) .
  3. Engine codes BDC and BGD «SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-1997-2005/remont/auxiliary-emission-control-systems/#20l-exhaust-system-emission-controls-engine-codes-aeg-avh-azg-bdc-bev-bgd-hatchback) .

Pull off/disconnect and lay aside all electrical harnesses from transmission, alternator, and starter.

Pull off/disconnect all electrical connections as necessary from engine and lay aside.

Remove bolts for pendulum support -arrows-.

Scheme 156

Scheme 156
Scheme 156

If equipped, remove the protective cap for the inner right CV joint from the engine.

Remove the right drive axle, and remove the left drive axle on the transmission Removal and Installation .

Remove the front exhaust pipe together with the catalytic converter

  1. Engine code AEG «EXHAUST MANIFOLD, FRONT EXHAUST PIPE AND ATTACHMENTS ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-1997-2005/remont/auxiliary-emission-control-systems/#20l-exhaust-system-emission-controls-engine-codes-aeg-avh-azg-bdc-bev-bgd-hatchback) .
  2. Engine codes AVH, AZG, BDC, BEV and BGD «EXHAUST MANIFOLD, FRONT EXHAUST PIPE AND ATTACHMENTS ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-1997-2005/remont/auxiliary-emission-control-systems/#20l-exhaust-system-emission-controls-engine-codes-aeg-avh-azg-bdc-bev-bgd-hatchback) .

If equipped, remove the oil pan guard OIL PAN ASSEMBLY OVERVIEW .

Set engine support T10012 on engine/transmission jack V.A.G 1383 A.

Remove the lower coolant hose bracket from the cylinder block. The threaded hole is needed for attaching the engine support T10012.

Fasten the engine support T10012 to the front of the cylinder block using an M10 x 25 / 8.8 bolt to approximately 40 Nm.

Scheme 157

Scheme 157
Scheme 157

Hand-tighten the nut on the exhaust side.

Lift engine and transmission slightly using the engine/transmission jack V.A.G 1383 A.

From above, remove the engine mount bolts -arrows- from the engine support.

Scheme 158

Scheme 158
Scheme 158

Note. Use step ladder VAS 5085 to remove bolts.

Remove transmission mount bolts -arrows- from transmission bracket from above.

Scheme 159

Scheme 159
Scheme 159

Carefully lower engine with transmission.

While doing this, route the power steering pressure line on the transmission.

Note. When lowering, carefully guide the engine and transmission to prevent damaging the body, hoses and lines.

SECURING ENGINE ON ASSEMBLY STAND

Secure the engine to the assembly stand using the engine and transmission holder VW 540 and the supplementary set VW 540/1 B on the holding fixture VW 313.

Procedure

Move the engine/transmission subassembly with the engine/transmission jack V.A.G 1383 A to a workbench.

Scheme 160

Scheme 160: SECURING ENGINE ON ASSEMBLY STAND
Scheme 160: SECURING ENGINE ON ASSEMBLY STAND

Lower the engine/transmission assembly so that transmission makes contact.

Remove connecting bolts for engine/transmission.

Press transmission off from engine.

With Automatic Transmission

Remove the nuts from the torque converter.

Remove the hoses from the ATF cooler.

After separating engine from transmission, secure the torque converter to prevent it from "falling out".

Continuation for All

Attach Engine sling 2024 A as follows and lift engine from engine/transmission jack V.A.G 1383 A using workshop crane.

Scheme 161

Scheme 161
Scheme 161

Belt pulley side: 3. Hole of rail in position 2

Dual-mass flywheel side: 3. Hole of rail in position 8

WARNINGUse securing pins at hooks and pins.

Note. The peg positions on the carrying strap marked with 1 to 4 face the belt pulley. The bores in the hole rail are counted from the hook.

Secure the engine with the engine and transmission holder VW 540 and the supplementary set VW 540/1 B to the holding fixture VW 313. The fitting sleeves must be removed.

ENGINE, INSTALLING

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

CAUTIONWhen 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, EVAP canister system, 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.

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

Engage intermediate plate at sealing flange and slide onto alignment bushings -arrows-.

Scheme 162

Scheme 162
Scheme 162

With Manual Transmission

If necessary, check centering of clutch drive plate.

Check clutch release bearing for wear and replace if necessary.

Lightly grease clutch release bearing, guide sleeve for release bearing and input shaft splines with G 000 100.

Install the hydraulic clutch slave cylinder, refer to [For transmission(s) 02J] HYDRAULIC SYSTEM ASSEMBLY OVERVIEW , or refer to [For transmission(s) 0A4] HYDRAULIC SYSTEM ASSEMBLY OVERVIEW , or refer to [For transmission(s) 02M] CLUTCH SLAVE CYLINDER .

Install the shift mechanism, refer to [For transmission(s) 02E] SHIFT MECHANISM , or refer to [For transmission(s) 02J] Removal and Installation , or refer to [For transmission(s) 0A4] SHIFT MECHANISM , or refer to [For transmission(s) 02M] GEAR SELECTOR MECHANISM

If necessary, adjust the shift mechanism, refer to [For transmission(s) 02E] Diagnosis and Testing , or refer to [For transmission(s) 02J] Diagnosis and Testing , or refer to [For transmission(s) 0A4] Diagnosis and Testing , or refer to [For transmission(s) 02M] Diagnosis and Testing

With Automatic Transmission 01M

Only use nuts for mounting the torque converter to the drive plate.

Install the selector lever cable to the transmission, refer to [For transmission(s) 01M] Removal and Installation .

If necessary, adjust the shift mechanism [For transmission(s) 01M] Diagnosis and Testing .

With Automatic Transmission 09G

Only use nuts for mounting the torque converter to the drive plate.

Install the selector lever cable to the transmission, refer to [For transmission(s) 09G] SELECTOR LEVER CABLE .

If necessary, adjust the shift mechanism [For transmission(s) 09G] Diagnosis and Testing .

Continuation for All

When installing engine/transmission assembly, check for clearance to subframe as well as to radiator.

While doing this, route the power steering pressure line on the transmission.

Align engine and transmission mountings ENGINE AND TRANSMISSION MOUNT, ALIGNMENT SPECIFICATIONS .

Secure the engine and transmission ENGINE AND TRANSMISSION MOUNT TIGHTENING SPECIFICATIONS .

Subframe tightening specifications ENGINE AND TRANSMISSION MOUNT TIGHTENING SPECIFICATIONS .

Install the right drive axle, and install the left drive axle on the transmission Removal and Installation .

If equipped, install the protective cap for the inner right CV joint.

Install the front exhaust pipe together with the catalytic converter

  1. Engine code AEG «EXHAUST MANIFOLD, FRONT EXHAUST PIPE AND ATTACHMENTS ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-1997-2005/remont/auxiliary-emission-control-systems/#20l-exhaust-system-emission-controls-engine-codes-aeg-avh-azg-bdc-bev-bgd-hatchback) .
  2. Engine codes AVH, AZG, BDC, BEV and BGD «EXHAUST MANIFOLD, FRONT EXHAUST PIPE AND ATTACHMENTS ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-1997-2005/remont/auxiliary-emission-control-systems/#20l-exhaust-system-emission-controls-engine-codes-aeg-avh-azg-bdc-bev-bgd-hatchback) .

Install the power steering pump Description and Operation .

Electrical connections and routing Wiring .

Install ribbed belt RIBBED BELT .

Install the secondary air injection (AIR) pump motor with the bracket

  1. Engine code AEG through 05.99 «SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-1997-2005/remont/auxiliary-emission-control-systems/#20l-exhaust-system-emission-controls-engine-codes-aeg-avh-azg-bdc-bev-bgd-hatchback) .
  2. Engine codes AVH, AZG, BEV and AEG from 06.99 «SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-1997-2005/remont/auxiliary-emission-control-systems/#20l-exhaust-system-emission-controls-engine-codes-aeg-avh-azg-bdc-bev-bgd-hatchback) .
  3. Engine codes BDC and BGD «SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-1997-2005/remont/auxiliary-emission-control-systems/#20l-exhaust-system-emission-controls-engine-codes-aeg-avh-azg-bdc-bev-bgd-hatchback) .

Install the center, left and right noise insulation Description and Operation .

Without Electronic Power Control

Adjust accelerator pedal (AP) cable ACCELERATOR PEDAL CABLE, ADJUSTING .

Continuation for All

Check DTC memory of all control modules, repair all stored malfunctions, and erase DTC memory afterwards vehicle diagnosis, testing and information system VAS 5051 ; guided fault finding; vehicle system test, or vehicle diagnosis and service information system VAS 5052 ; on board diagnostic (OBD).

Perform road test and check DTC memory of all control modules again.

Note. Observe safety precautions that apply to road tests SAFETY PRECAUTIONS .

Scheme 163

Scheme 163: SPECIAL TOOLS
Scheme 163: SPECIAL TOOLS

Special tools and workshop equipment required

  1. Lifting tackle 2024 A
  2. Engine mount T10012
  3. Holding fixture VW 313
  4. Engine and transmission holder VW 540
  5. Shop crane V.A.G 1202 A
  6. Drip tray V.A.G 1306

Scheme 164

Scheme 164
Scheme 164

Special tools and workshop equipment required

  1. Torque wrench V.A.G 1331
  2. Torque wrench V.A.G 1332
  3. Engine/transmission jack V.A.G 1383 A
  4. Pliers for spring type clips VAS 5024
  5. Spacers VW 540/1 B
  6. Step ladder VAS 5085

See also:
• [For transmission(s) 02J] TRANSMISSION TO ENGINE TIGHTENING SPECIFICATIONS
• [For transmission(s) 01M] FASTENER TIGHTENING SPECIFICATIONS
• Removal and Installation
• Removal and Installation
• AIR FILTER ASSEMBLY OVERVIEW
• [For transmission(s) 02J] Removal and Installation
• [For transmission(s) 02J] HYDRAULIC SYSTEM ASSEMBLY OVERVIEW
• [For transmission(s) 01M] Removal and Installation
• Description and Operation
• COOLING SYSTEM, DRAINING AND FILLING
• RIBBED BELT
• Description and Operation
• Description and Operation
• SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW
• OIL PAN ASSEMBLY OVERVIEW
• [For transmission(s) 02J] Diagnosis and Testing
• Wiring
• ACCELERATOR PEDAL CABLE, ADJUSTING
• SAFETY PRECAUTIONS
• ENGINE AND TRANSMISSION MOUNT TIGHTENING SPECIFICATIONS
• ENGINE AND TRANSMISSION MOUNT, ALIGNMENT SPECIFICATIONS

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