Volkswagen MK4 and New Beetle All Transverse Engines 1998-2006


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Volkswagen MK4 and New Beetle All Transverse Engines 1998-2006 Transmission Mount Installation

Proper service and repair procedures are vital to the safe, reliable operation of all motor vehicles as well as the personal safety of those performing the repairs. Standard safety procedures and precautions (including use of safety goggles and proper tools and equipment) should be followed at all times to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

INTRODUCTION ECS Tun i n g Vo l k s wa g e n M K 4 Per fo r mance Transmissio n M o u nt The ECS Tuning Volkswagen MK4 Performance Transmission Mount offers the following features and benefits: Constructed of strong and lightweight 6061-T6 billet aluminum Black anodized for corrosion resistance Precisely formulated polyurethane for the perfect combination of durability and feel In-house designed by ECS Tuning engineers Includes all new mounting hardware Easy installation

ECS Difficulty Gauge

The transmission mount on your MK4 Volkswagen is one of only two mounts that hold the weight of the entire drivetrain. Constantly enduring all the hard acceleration and deceleration you can throw at it, these mounts can become worn quickly, and the soft compound of an original mount can rob precious horsepower. With our new Performance Transmission Mount, put your power to the ground with a quick and easy installation that you can perform in an afternoon. Before you begin, read and familiarize yourself with these instructions and make sure you have all the required tools on hand. Thank you for purchasing our ECS Tuning Performance Transmission Mount. We appreciate your business!

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1 - Easy 2 - Moderate

Pro - 4 Advanced - 3

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

TABLE OF CONTENTS Kit Contents......................................................................................................................pg.4 Required Tools and Equipment.................................................................................pg.5 Shop Supplies and Materials......................................................................................pg.6 Installation and Safety Notes.....................................................................................pg.7 Removing the Original Transmission Mount........................................................pg.8 Installing the New Performance Transmission Mount......................................pg.14 Torque Specifications....................................................................................................pg.20 Schwaben Tools..............................................................................................................pg.21

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

1.800.924.5172

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

KIT CONTENTS

Fully Assembled ECS Tuning Performance Transmission Mount

All New Mounting Hardware

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

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REQUIRED TOOLS

VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

Note: The tools required for each step will be listed by the step number throughout these instructions.

Below is a list of the tools we used to install our ECS Tuning Performance Transmission Mount. Additional tools may be required for any issues that arise during installation such as rust, corrosion, or broken and stripped fasteners. Tools with a part number listed are available on our website - click on their ES# link to view them. • 3/8” Drive Ratchet........................................................................ ES#2765902 • 3/8” Drive Torque Wrench......................................................... ES#2221245 • 3/8” Drive Sockets: 13mm, 16mm............................................ ES#2763772 • 3/8” Drive Extensions • Open/Boxed End Wrenches: 13mm........................................ ES#2765907 • Hydraulic Floor Jack.................................................................... ES#240941 • Torx Drivers (for insulation panel removal)..................................ES#11417 • 1/2” Drive Sockets: 18mm • 1/2” Drive Ratchet • 1/2” Drive Extensions • 1/2” Drive Torque Wrench......................................................... ES#2221244 • 1/2” Drive Breaker Bar................................................................. ES#2776653

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

SHOP SUPPLIES AND MATERIALS Standard Shop Supply Recommendations: We recommend that you have a standard inventory of automotive shop supplies before beginning this or any automotive repair procedure. The following list outlines the basic shop supplies that we like to keep on hand. Shop supplies with a hyperlink are available on our website. • • • • • • • • • • • • • • •

Hand Cleaner/Degreaser - Click Here Pig Mats - for protecting your garage floor and work area from spills and stains - Click Here Spray detailer - for rapid cleaning of anything that comes into contact with your paint such as brake fluid - Click Here Micro Fiber Towels - for cleaning the paint on your car - Click Here Latex Gloves - for the extra oily and dirty jobs - Click Here Medium and High Strength Loctite Thread lock compound - to prevent bolts from backing out - Click Here Anti-Seize Compound - to prevent seizing, galling, and corrosion of fasteners - Click Here Aerosol Brake/Parts Cleaner - for cleaning and degreasing parts Shop Rags - used for wiping hands, tools, and parts Penetrating oil - for helping to free rusted or stuck bolts and nuts Mechanics wire - for securing components out of the way Silicone spray lube - for rubber components such as exhaust hangers Paint Marker - for marking installation positions or bolts during a torquing sequence Plastic Wire Ties/Zip Ties - for routing and securing wiring harnesses or vacuum hoses Electrical tape - for wrapping wiring harnesses or temporary securing of small components

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

INSTALLATION NOTES • • • • •

RH refers to the passenger side of the vehicle. LH refers to the driver side of the vehicle. Always use the proper torque specifications. If applicable to this installation, torque specifications will be listed throughout the document and at the end as well. Please read all of these instructions and familiarize yourself with the complete process BEFORE you begin.

GENERAL PREPARATION AND SAFETY INFORMATION ECS Tuning cares about your health and safety. Please read the following safety information. This information pertains to automotive service in general, and while it may not pertain to every job you do, please remember and share these important safety tips. • • • • • • • • • •

Park your car in a safe, well lit, level area. Shut the engine off and remove the key from the ignition switch. Make sure any remote start devices are properly disabled. ALWAYS wear safety glasses. Make sure the parking brake is applied until the vehicle is safely lifted and supported. If using an automotive lift, be sure and utilize the factory specified lift points. Lifting a vehicle in an incorrect location can cause damage to the suspension/running gear. When lifting a vehicle using a jack, always utilize the factory specified lift points. Lifting a vehicle in an incorrect location can cause damage to the suspension/running gear. ALWAYS support the vehicle with jack stands. ALWAYS read and follow all safety information and warnings for the equipment you are using.

Never get underneath a vehicle that is supported only by a jack. Always make sure that the vehicle is securely supported on jack stands.

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

1.800.924.5172

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

REMOVING THE ORIGINAL TRANSMISSION MOUNT Step 1: The first step is to remove either your original air box or aftermarket intake system, whichever you have installed. The transmission mount is located directly underneath the location of the original air box.

Transmission mount

Step 2: Pull up the cowl seal on the LH side to expose the top lip of the wiring harness channel cover.

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

1.800.924.5172

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

REMOVING THE ORIGINAL TRANSMISSION MOUNT Step 3: Unclip the wiring harness channel cover at the four locations shown in the picture.

Step 4: Pivot the wiring harness channel cover upwards, unhook it at the bottom and remove it.

NOTE

Removing this cover will give you access through the harness channel to two of the transmission mount bolts.

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

1.800.924.5172

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Unhook

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

REMOVING THE ORIGINAL TRANSMISSION MOUNT Step 5:

Torx Drivers

Underneath the vehicle, remove the lower insulation panel or skid plate, whichever you have installed, so you can access the bottom of the transmission.

Step 6:

Hydraulic Floor Jack

Place a hydraulic jack underneath the transmission and raise it up until the jack pad contacts the transmission case.

NOTE

Be sure your jack has a protective rubber pad on it or use a block of wood to prevent damage to the transmission case.

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

1.800.924.5172

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

REMOVING THE ORIGINAL TRANSMISSION MOUNT Step 7:

18mm Socket, 1/2” Ratchet, Extension

Remove the two bolts securing the transmission mount to the transmission bracket. Discard both bolts.

Step 8:

13mm Socket, 3/8” Ratchet, Extension

Pull back the wiring in the harness channel and remove the M8 bracket bolt that is accessible through a hole in the channel. Discard the bolt.

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

1.800.924.5172

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

REMOVING THE ORIGINAL TRANSMISSION MOUNT Step 9:

16mm Socket, 3/8” Ratchet, Extension

Locate the two transmission mount to body bolts. Remove the first one then proceed to the next step.

2. 1.

Step 10:

16mm Socket, 3/8” Ratchet, Extension

The second bolt can be removed by moving the wiring in the harness channel to expose a hole directly above the bolt. The socket and extension will pass through the hole for easy access. Discard both bolts.

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

1.800.924.5172

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

REMOVING THE ORIGINAL TRANSMISSION MOUNT Step 11: Lower the jack only about one inch, but be careful to not let it completely drop down.

Step 12: Remove the original transmission mount from the car.

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

1.800.924.5172

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

INSTALLING THE NEW ECS PERFORMANCE TRANSMISSION MOUNT Step 1: Position the new ECS mount in place.

Step 2:

16mm Socket, 3/8” Ratchet, Extension

Thread in both new mount to body bolts until they are fully seated but do not tighten them at this time.

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

INSTALLING THE NEW ECS PERFORMANCE TRANSMISSION MOUNT Step 3: Inspect the mounting hole for the M8 bracket bolt. This is an enlarged hole to allow for manufacturing tolerances in the body. It does not need to be centered, however there needs to be enough clearance so you can start the new M8 bracket bolt without cross threading it. If there is not enough clearance as shown in the picture on the left, rotate the mount slightly at it’s base until you are able to start the bolt. Once you have enough clearance as shown in the picture on the right, install the new M8 bracket bolt included with the kit and thread it in until it is fully seated but do not tighten it at this time.

Step 4:

16mm Socket, Torque Wrench, Breaker Bar

Torque both of the transmission mount to body bolts to 40 Nm (30 Ft-lbs) + 90 degrees.

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

INSTALLING THE NEW ECS PERFORMANCE TRANSMISSION MOUNT Step 5:

13mm Socket, 3/8” Torque Wrench

Torque the M8 bracket bolt to the specification for your application: 1.8L Engine...............................................................25Nm (18 Ft-lbs) 1.9L Engine...............................................................25 Nm (18 Ft-lbs) 2.0L Engine...............................................................25 Nm (18 Ft-lbs) 2.8L AFP Engine......................................................25 Nm (18 Ft-lbs) 2.8L BDF Engine......................................................20 Nm (15 Ft-lbs) + 90 degrees 3.2L BJS Engine.......................................................25 Nm (18 Ft-lbs)

Step 6: Raise the transmission up with the floor jack until the transmission bracket is contacting the transmission mount.

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

INSTALLING THE NEW ECS PERFORMANCE TRANSMISSION MOUNT Step 7: Look down through the transmission mount and move the drivetrain around as necessary to visually line up the bolt holes for the transmission bracket.

Step 8:

18mm Socket, Ratchet, Extension

Install both of the new transmission mount to bracket bolts and thread them all the way in just until they are fully seated, then back them off one complete revolution (360 degrees). Do not tighten them at this time.

NOTE

To avoid cross threading, move the drivetrain around as necessary for the bolts to thread in easily.

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

1.800.924.5172

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

INSTALLING THE NEW ECS PERFORMANCE TRANSMISSION MOUNT Step 9: Fully lower the transmission jack.

Step 10:

18mm Socket, 1/2” Torque Wrench, Breaker Bar

Make sure the edge of the transmission mount is lined up with the edge of the mount bracket, then thread the two transmission mount to bracket bolts all the way in until they are fully seated and torque them to the following specification for your application: 1.8L Engine...............................................................100 Nm (74 Ft-lbs) 1.9L ALH Engine......................................................60 Nm (44 Ft-lbs) + 90 degrees 1.9L BEW Engine......................................................100 Nm (74 Ft-lbs) 2.0L Engine...............................................................100 Nm (74 Ft-lbs) 2.8L AFP Engine......................................................60 Nm (44 Ft-lbs) + 90 degrees 2.8L BDF Engine......................................................100 Nm (74 Ft-lbs) 3.2L BJS Engine.......................................................100 Nm (74 Ft-lbs) ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

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Make sure edges line up

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

FINAL INSTALLATION STEPS Reinstall the wiring harness channel cover. Reinstall the cowl seal. Reinstall your original air box or intake system. Reinstall the lower insulation panel or skid plate.

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

1.800.924.5172

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

TORQUE SPECIFICATIONS Transmission mount to body bolts: 40 Nm (30 Ft-lbs) + 90 degrees

Transmission mount to bracket bolts: 1.8L Engine...............................................................100 Nm (74 Ft-lbs) 1.9L ALH Engine......................................................60 Nm (44 Ft-lbs) + 90 degrees 1.9L BEW Engine......................................................100 Nm (74 Ft-lbs) 2.0L Engine...............................................................100 Nm (74 Ft-lbs) 2.8L AFP Engine......................................................60 Nm (44 Ft-lbs) + 90 degrees 2.8L BDF Engine......................................................100 Nm (74 Ft-lbs) 3.2L BJS Engine.......................................................100 Nm (74 Ft-lbs)

Transmission M8 bracket bolt: 1.8L Engine...............................................................25Nm (18 Ft-lbs) 1.9L Engine...............................................................25 Nm (18 Ft-lbs) 2.0L Engine...............................................................25 Nm (18 Ft-lbs) 2.8L AFP Engine......................................................25 Nm (18 Ft-lbs) 2.8L BDF Engine......................................................20 Nm (15 Ft-lbs) + 90 degrees 3.2L BJS Engine.......................................................25 Nm (18 Ft-lbs) • A note about torque to yield or “stretch” bolts: Many bolts will have a torque specification listed in the format - xx Nm (xx Ft-lbs) + xx degrees. These bolts are torque to yield bolts, commonly referred to as “stretch” bolts. The correct procedure for torquing these bolts is: Stage One - torque them to the Nm or Ft-lb specification. Stage Two - tighten each one the additional specified number of degrees. To prevent over torquing it is important to mark each fastener with paint immediately after performing the second stage or “stretching” of the bolts. Note that some bolts may have two stages of torquing before the final stage of “stretching” the bolts. ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

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VOLKSWAGEN MK4 AND NEW BEETLE ECS TRANSMISSION MOUNT INSTALLATION

ES#2917900

SCHWABEN - BUILD THE ULTIMATE TOOL COLLECTION At ECS Tuning, we carry a line of high quality Schwaben tools and equipment to help you build your ultimate tool collection. Never before has affordability and quality been so closely related. Our entire Schwaben line is subjected to strict in house testing for strength and durability. See what we have to offer and equip your garage without breaking the bank.

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281

1.800.924.5172

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Your ECS Tuning Performance Transmission Mount Installation is complete!

These instructions are provided as a courtesy by ECS Tuning Proper service and repair procedures are vital to the safe, reliable operation of all motor vehicles as well as the personal safety of those performing the repairs. Standard safety procedures and precautions (including use of safety goggles and proper tools and equipment) should be followed at all times to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.

Although this material has been prepared with the intent to provide reliable information, no warranty (express or implied) is made as to its accuracy or completeness. Neither is any liability assumed for loss or damage resulting from reliance on this material. SPECIFICALLY, NO WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER WARRANTY IS MADE OR TO BE IMPLIED WITH RESPECT TO THIS MATERIAL. In no event will ECS Tuning, Incorporated or its affiliates be liable for any damages, direct or indirect, consequential or compensatory, arising out of the use of this material.