Transmission, Installing: Installing

-- Prepare the Support : T90003 : the bracket -arrow- must be turned so that the longer side faces upward.

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CAUTION:

Risk of damaging the transmission by mixing ATF and transmission fluid (MTF) through the same bleeder.

- The transmission filled with ATF and (MTF) transmission fluid must be tilted a maximum of 15° in lateral and longitudinal direction.

-- Comply with the angle of inclination.

Fig 1: Transmission Maximum Tilt

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-- Install the tunnel crossmember on the transmission. Refer to Tunnel Crossmember, Removing and Installing .

-- Position the transmission on the mount and secure with the Tensioning Strap : T10523 .

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Conditions

The mount may not be set on the transmission fluid pan
The tensioning strap must be guided under the coolant pipes on the transmission.

-- Insert the Clutch Module Assembly Aid :T40169 in the transmission housing and the flywheel from below.

Fig 2: Insert Assembly Aid T40169 Into Transmission Housing

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-- The tool must grip into the semicircular hole and also in the hole -arrow A- and -arrow B-.

Fig 3: Inserting Clutch Module Assembly Aid T40169 Into Transmission And Dual Mass Flywheel

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-- There is only one inspection opening -arrow B- on the edge. Rotate the flywheel as needed.

-- Insert the Clutch Module Transportation Lock :T40170 from below into the transmission housing and secure it to the flange shaft -1-.

Fig 4: Identifying Transportation Lock T40170

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-- Clean the contact surface -1- on the lower timing chain cover and on the sealing piece -2- with Cleaning Solution "D 009 401 04".

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-- Bond the sealing piece to the lower timing chain cover.

Vehicles with a 4-cylinder TDI engine:

-- Inspect the aluminum bolts -3 through 9- used to connect the engine to the transmission to see if they can be used again and mark them.

Fig 5: Transmission Mounting Bolts and Alignment Sleeves (4-Cylinder TDI Engine)

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-- Inspect the aluminum bolt -2- used to connect the starter to the transmission to see if it can be used again and mark it.

-- Make sure that the alignment sleeves -A- for centering the engine and transmission are inserted in the cylinder block.

Continuation for all vehicles

Vehicles with 4-cylinder TFSI or 6-cylinder TDI engine:

-- Inspect the aluminum bolts -1 through 8- used to connect the engine to the transmission to see if they can be used again and mark them.

Fig 6: Transmission Mounting Bolts and Alignment Sleeves (4-Cylinder FSI Engine)

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-- Inspect the aluminum bolt -2- used to connect the starter to the transmission to see if it can be used again and mark it.

-- Make sure that the alignment sleeves -arrows- for centering the engine and transmission are inserted in the cylinder block.

Continuation for all vehicles

-- Lift the transmission -3- and tunnel crossmember -5-.

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-- Position the transmission on the engine.

-- Introduce the starter.

Vehicles with a 4-cylinder TDI engine:

-- Install bolts -1 through 9-. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .

Fig 7: Transmission Mounting Bolts and Alignment Sleeves (4-Cylinder TDI Engine)

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Continuation for all vehicles

Vehicles with 4-cylinder TFSI or 6-cylinder TDI engine:

-- Install bolts -1 through 10-. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .

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Continuation for all vehicles

-- Install the bolts -arrows- for the tunnel crossmember -1-. Refer to Overview - Assembly Mounts .

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-- Remove the Engine and Gearbox Jack :VAS 6931 with the Support :T90003 .

-- Remove the engine support supplement set. Refer to ENGINE, SUPPORTING IN INSTALLATION POSITION (4 CYL) , or ENGINE, SUPPORTING IN INSTALLATION POSITION (6 CYL) .

-- Turn the crankshaft on the vibration damper 360° in the direction of engine rotation.

-- Remove the Clutch Module Transportation Lock :T40170 .

Fig 8: Identifying Transportation Lock T40170

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Conditions

If the vibration damper does not lay flat on the drive plate, insert the Clutch Module Transportation Lock and turn the crankshaft another 360°.

-- Install the first bolt -arrow-, tighten to 10 Nm, loosen and then tighten to 2 Nm (hand-tight).

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-- Remove the Clutch Module Assembly Aid :T40169 .

Fig 9: Insert Assembly Aid T40169 Into Transmission Housing

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Vehicles with 4-Cylinder Engine (Three Bolts):

-- Turn the crankshaft on the vibration damper 120° in the direction of the engine rotation with a large offset open-end wrench.

-- Install the next bolt in this crankshaft position and tighten.

-- Turn the crankshaft another 120° in the direction of engine rotation and install the next bolt and tighten.

-- - Turn the crankshaft another 120° in the direction of engine rotation and tighten the last bolt.

Continuation for all vehicles

Vehicles with 6-Cylinder Engine (Six Bolts):

-- Turn the crankshaft on the vibration damper 180° in the direction of engine rotation. Install bolt -4- and tighten.

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-- Turn the crankshaft another 60° in the direction of engine rotation. Install bolts -5- and -6- and tighten.

-- - Turn the crankshaft another 60° in the direction of engine rotation and tighten bolt -1-.

-- Turn the crankshaft another 60° in the direction of engine rotation. Install bolts -2- and -3- and tighten.

Continuation for all vehicles

-- Install the cover -1-.

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CAUTION:

Risk of destroying due to electrostatic charge.

- Do not touch the connector terminals.

- Touch a grounded object (for example the hoist) and discharge any static electricity.

-- Connect the connectors.

-- If removed, install the driveshaft. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

-- If removed, install the Reducing Agent Injector 2 - N758. Refer to the appropriate service information .

-- If removed, install the slip catalyst. Refer to the appropriate service information .

-- If removed, install the particulate filter. Refer to PARTICULATE FILTER, REMOVING AND INSTALLING .

-- If removed, install the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING (4 CYL) , or CATALYTIC CONVERTER, REMOVING AND INSTALLING (6 CYL) .

-- If removed, install the plenum chamber bulkhead. Refer to PLENUM CHAMBER BULKHEAD, REMOVING AND INSTALLING .

-- Install the coolant pipes. Refer to OVERVIEW - COOLANT PIPES (4 CYL) , or OVERVIEW - COOLANT PIPES (6 CYL) .

-- Install the front exhaust pipe. Refer to the appropriate service information .

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

-- Install the subframe crossbrace. Refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .

-- Bleed the cooling system if the drained coolant is less than or equal to 0.5 Liter, otherwise fill and bleed the cooling system. Refer to COOLANT, DRAINING AND FILLING .

-- Install the steering intermediate shaft. Refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

-- Connect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

If transmission fluid and ATF have been drained:

-- Fill the transmission fluid. Refer to Transmission Fluid, Draining and Filling .

-- Add ATF. Refer to ATF, Draining and Filling .

Continuation

If components in the transmission were replaced:

-- After installing the transmission, perform the following functions: Refer to DIAGNOSTIC ENTRY .

Distance Sensors, Calibration
Parking Lock, Adaptation

Continuation