Transmission, installing (vehicles with 4.2 ltr. MPI engine): Notes

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NOTE:

Re-attach all cable ties at the same locations when re-installing.
Secure all hose connections with the correct hose clips (as original equipment) .
Re-attach heat shield sleeves at the same locations when re-installing.
Replace self-locking nuts.

Fig 1: Checking Torque Converter Is Correctly Positioned

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Before installing transmission, make sure that the torque converter is properly installed in transmission.

If torque converter is correctly installed, the depth between contact surfaces at tapped holes on torque converter and contact surface of torque converter bell housing is at least 19 mm.

CAUTION: If the torque converter is not installed correctly, the torque converter drive lugs or the ATF pump will be seriously damaged when the transmission is joined to the engine.

Fig 2: Identifying Engine/Transmission Threaded Connections

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Before installing transmission, check for correct positioning of dowel sleeves - A - at cylinder block. Install new dowel sleeves if necessary.
If an intermediate plate was installed between engine and transmission, reinstall plate in same position.
When pushing engine and transmission together, make sure that no cables, lines, etc. can become trapped.

CAUTION: Before and while tightening the bolts on the engine/transmission flange keep checking that the torque converter can still be rotated behind the drive plate. If the converter cannot be turned, it must be assumed that it has not been installed correctly and the drive lugs on the converter or the ATF pump will be damaged when the bolts are fully tightened.

Bolt transmission onto engine Illustration of transmission flange .
Use new ribbed bolts to secure torque converter to drive plate. Use only correct bolts (same as original equipment) .

Fig 3: Inserting Guide Pin Of Adapter T40058

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert guide pin of adapter T40058 so that the large diameter - arrow 1 - faces engine. The smaller diameter - arrow 2 - faces adapter.
Counter-hold crankshaft using adapter T40058 to secure torque converter bolts.

Fig 4: Removing Bolts From Torque Converter Through Opening For Starter

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install 3 torque converter bolts through opening for starter (finger-tight). Turn crankshaft ¹ /₃ of a turn to access one bolt after another.
Tighten torque converter bolts to torque (turning crankshaft ¹ /₃ turn each time).

Fig 5: Identifying Bolt, Heat Shield, Bolt & Engine Speed (RPM) Sensor G28

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert engine speed (RPM) sensor G28 - item A - into bell housing (top left) and tighten bolt - 1 -.
Install heat shield - B - and tighten bolt - 2 - (transmission/engine bolt connection Illustration of transmission flange )

Fig 6: Location Of ATF Lines At Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert ATF cooling lines - A - and - B - into transmission as far as possible and tighten bolt - 2 -.

Fig 7: Pressing Selector Lever Cable Onto Ball Head Of Selector Shaft Lever

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press selector lever cable - 1 - onto selector shaft lever - 3 -.
Install starter →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.
Install transmission support with transmission mounting → Transmission support and transmission mounting, removing and installing (left and right) .
Install front exhaust pipes →
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
- 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
.

Fig 8: Checking Holes Align Using Testing Mandrel 3393

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If measurement performed with locating pin 3393 during removal showed that holes - 1 - and - 2 - were aligned:

Install subframe, observing tightening sequence → 40 - FRONT SUSPENSION .

If measurement performed with locating pin 3393 during removal showed that holes - 1 - and - 2 - were NOT aligned:

Only tighten bolts for subframe to tightening torque setting, do not yet turn further (wait until wheel alignment has been carried out).

CAUTION: The vehicle must not be driven.

Clean ATF lines and ATF cooler → ATF cooling lines and ATF cooler, cleaning .
Secure ATF lines to transmission and engine → ATF cooling lines .

Fig 9: Identifying Cable Support Bracket To Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Bolt on support bracket for selector lever cable - arrows -.
Secure driveshaft to transmission →
- 39 FINAL DRIVE, DIFFERENTIAL for REAR FINAL DRIVE
- 39 - FINAL DRIVE, DIFFERENTIAL for REAR FINAL DRIVE 0AR
.

Fig 10: Removing/Installing Heat Shield For Driveshaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure heat shield - A - for driveshaft - arrows -.
Install exhaust system free of stress →
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
- 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
.
Bolt drive axles to flange shafts → 40 - FRONT SUSPENSION .

Fig 11: Drive Axle Heat Shield

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install heat shields - arrow - for drive axles (left and right).
Adjust selector lever cable → Selector lever cable, checking and adjusting .
Check oil level in final drive (front) → Front final drive gear oil .
Check oil level in transfer gear→ Transfer gear oil .

Follow steps required after connecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.
Check ATF level → ATF level, checking and correcting .
If necessary, carry out wheel alignment → 44 - WHEELS, TIRES, VEHICLE ALIGNMENT .

CAUTION: After wheel alignment tighten subframe bolts to their final torque setting.

Tightening torques

NOTE:

Tightening torques only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
Lubricants such as engine or transmission oil may be used, but do not use graphite lubricant.
Do not use parts which have been degreased.

Drive plate to torque converter	Nm
Ribbed bolts, M10x1x21.5 (3x) * See note* See note
4.2 ltr. MPI engine	85

*Replace bolts.

*Use new bolts (same as original equipment) .