Transmission, removing and installing (vehicles with 4-cylinder engine): Installing

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Refer to work sequence "removing transmission" for the special tools required.

Clean all threaded holes in which self-locking bolts are to be threaded of remaining locking fluid using a tap.

NOTE:

Always replace self-locking nuts and bolts.

Clean splines of input shaft and lightly grease with grease G 000 100.

Clutch disc must be able to be moved back and forth on input shaft.

Make sure centering sleeves for engine to transmission are installed in cylinder block. Install if necessary.
Make sure intermediate plate is correctly seated on engine.

Transmission support 3282 must be equipped with adjustment plate 3282/27 to install transmission "02Y".

Align transmission support arms to correspond with holes in adjustment plate.

Fig 1: Bolting Transmission Support Elements

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Screw in attachments - A - , as depicted on adjustment plate.
Attach transmission to engine/transmission jack V.A.G 1383 A.
Align adjustment plate and transmission parallel to each other.
Secure transmission on transmission support 3282 using bolt - A -.

Fig 2: Transmission & Transmission Support 3282 With Bolt

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Place engine/transmission jack V.A.G 1383 A under vehicle, - arrow symbol B - on adjustment plate points in direction of travel.
Tilt transmission toward left via spindle for transmission support 3282.

Fig 3: Identifying Subframe

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Carefully lift transmission and guide past on subframe - arrow -.
Carefully press engine toward front with help of a 2nd technician.

NOTE:

While shifting engine, pay attention to all connecting lines and hoses.

Fig 4: Identifying Corner Of Oil Pan

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When raising transmission - 1 - , pay attention to corner - arrow - of oil pan - 2 -.
Change position of transmission via spindles of transmission support 3282 so that bevel gear transfer case can be guided past at oil pan.
Insert transmission.
Insert transmission carrier for bevel gear transfer case before installing in connecting bolts for engine/transmission.

NOTE:

Pay attention to power steering line.

Install one connection bolt for engine/transmission.
Install bolts for engine/transmission mount at bottom and tighten to tightening torque.

Fig 5: Identifying Selector Cable

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Insert selector cable - A - with actuator lever in direction of arrow.

Fig 6: Transmission Left Mount

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Install left transmission console - 1 - with new bolts - arrows - and tighten to tightening torque.

Fig 7: Identifying Engine/Transmission Jack V.A.G 1383/A With Universal Mount V.A.G 1359/2 Under Transmission

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Place engine/transmission jack V.A.G 1383/A with universal mount V.A.G 1359/2 under transmission and lift far enough until transmission stands parallel to transmission mount.
Align engine/transmission in installation position.

Fig 8: Left Assembly Mounting Hex Bolts & Left Mount

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Install new hex bolts - arrows - for left subframe mount - 2 - into console - 1 - and tighten to tightening torque.

NOTE:

Use step ladder VAS 5085 to install mounting bolts.

Fig 9: Locating Engine Carrier Bolts (Engine Side)

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Install new hex bolts - arrows - for right subframe mount in engine support → 10 - ENGINE - ASSEMBLY for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP (A4 PLATFORM), 10 - ENGINE - ASSEMBLY for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH (A4 PLATFORM), 10 - ENGINE - ASSEMBLY for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW (A4 PLATFORM) and 10 ENGINE - ASSEMBLY for 2.0 LITER 4-CYL. 2V ENGINE MECHANICAL, FUEL INJECTION & IGNITION, ENGINE CODE(S): AEG, AVH, AZG, BBW, BEV (A4 PLATFORM) .

NOTE:

Use step ladder VAS 5085 or equivalent to install mounting bolts.

CAUTION: Only remove engine support bridge V.A.G 10-222A when bolts for left and right subframe mounts are tightened to specified tightening torque.

NOTE:

Install engine/transmission bearing free of tension → 10 - ENGINE - ASSEMBLY for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP (A4 PLATFORM), 10 - ENGINE - ASSEMBLY for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH (A4 PLATFORM), 10 - ENGINE - ASSEMBLY for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW (A4 PLATFORM) and 10 ENGINE - ASSEMBLY for 2.0 LITER 4-CYL. 2V ENGINE MECHANICAL, FUEL INJECTION & IGNITION, ENGINE CODE(S): AEG, AVH, AZG, BBW, BEV (A4 PLATFORM) .

Fig 10: Small Cover Plate For Flywheel Behind Bevel Gear Transfer Case

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If installed, install small cover plate - A - for flywheel behind bevel gear transfer case - arrow -.
If installed, install turbocharger bracket → 21 - TURBOCHARGER, G-CHARGER for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP (A4 PLATFORM), 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH (A4 PLATFORM) and 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW (A4 PLATFORM) .

Fig 11: Engine & Bevel Gear Transfer Case Bolts

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Bolt transmission carrier for bevel gear transfer case to engine and bevel gear transfer case.

Note the following sequence when installing the transmission carrier:

Screw in all bolts hand-tight.
Tighten bolts - B - (M10 x 22) and bolt - C - (M8 x 22) first to 10 Nm.
Tighten bolts - A - (M10 x 45) to 50 Nm.
Tighten bolts to - B - to 40 Nm.

Tighten bolts - C - to 25 Nm.

Fig 12: Identifying Vacuum Diaphragm & Oil Return Line

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Bolt oil return line - 2 - for turbocharger to engine → 21 - TURBOCHARGER, G-CHARGER for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP (A4 PLATFORM), 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH (A4 PLATFORM) and 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW (A4 PLATFORM) .
Screw vacuum diaphragm - 1 - for charge pressure regulator valve to turbocharger - arrows - → 21 - TURBOCHARGER, G-CHARGER for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP (A4 PLATFORM), 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH (A4 PLATFORM) and 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW (A4 PLATFORM) .
Press engine/transmission assembly to bulkhead; while doing so, carefully guide pin of bevel gear transfer case into flange/driveshaft.

Fig 13: Identifying Sealing Ring In Driveshaft Flange

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NOTE:

Sealing ring in driveshaft flange must not be damaged when removing and installing transmission.
Replace driveshaft if damaged.
Slide driveshaft on guide pin horizontally.

Fig 14: Identifying Bevel Gear Transfer Case Flange Bolts

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Bolt driveshaft with flexible disc to bevel gear transfer case flange - arrows - and tighten to tightening torque.
Install front exhaust pipe to exhaust manifold and to turbocharger → 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP (A4 PLATFORM), 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH (A4 PLATFORM), 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW (A4 PLATFORM) and 26 EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 2V ENGINE MECHANICAL, FUEL INJECTION & IGNITION, ENGINE CODE(S): AEG, AVH, AZG, BBW, BEV (A4 PLATFORM) .

Fig 15: Identifying Pendulum Support & Bolts

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Install pendulum support - arrows A - and - arrows B - using new bolts → 40 FRONT SUSPENSION .
Install right drive axle and mount drive axles to transmission → 40 FRONT SUSPENSION .
Install catalytic converter and assemble exhaust system → 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP (A4 PLATFORM), 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH (A4 PLATFORM), 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW (A4 PLATFORM) and 26 EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 2V ENGINE MECHANICAL, FUEL INJECTION & IGNITION, ENGINE CODE(S): AEG, AVH, AZG, BBW, BEV (A4 PLATFORM) .
Insert starter and bolt firmly with lower bolt → 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Install bracket for power steering line to starter and to transmission.
Tighten top engine/transmission connecting bolts to correct tightening torque

Fig 16: Identifying Ground Strap At Engine/Transmission Upper Securing Bolt

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Install Ground (GND) strap to connecting bolt at top of engine/transmission - arrow -.

Fig 17: Identifying Speedometer Sensor Connector

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Connect connector to Speedometer Vehicle Speed Sensor (VSS).

Fig 18: Pushing Line/Hose, Pressing Down Clamp & Identifying Special Tool 3094

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Slide hose/line assembly in direction of arrow and press down clamp - arrow -.
Remove hose clamp 3094.
Install upper securing bolt on starter → 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Fig 19: Starter Wiring, Back-up Light Connector, Starter Cable Retainer & Starter Upper Securing Bolt

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Install cable bracket - A - on starter - arrow 3 -.
Connect connector for starter - arrow 1 - and back-up lights - arrow 2 -.

Fig 20: Identifying Support Bracket At Transmission

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Install cable mounting bracket on transmission and tighten bolts - arrows - to tightening torque.

Fig 21: Gate Selector Cable Relay Lever, Lock Washer, Gear Selector Cable, Nut & Power Steering Line

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Install shift cable - B - with transmission shift lever - arrow 2 -.
Tighten hex nut - arrow 2 - to tightening torque.
Secure selector cable - A - with actuator lever with locking washer - arrow 1 -.
Install power steering line - arrow 3 -.

Install battery holder → 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Fig 22: Identifying Air Cleaner Housing & Components

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Install complete air filter housing by tightening bolts - 4 - and - 5 - → 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWD (A4 PLATFORM), 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): AWW, AWP (A4 PLATFORM), 24 - MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO GENERIC SCAN TOOL, ENGINE CODE(S): AWP, AWW, AWD (A4 PLATFORM), 24 MULTIPORT FUEL INJECTION (MFI) for 2.0 LITER 4-CYL. 2V ENGINE MECHANICAL, FUEL INJECTION & IGNITION, ENGINE CODE(S): AEG, AVH, AZG, BBW, BEV (A4 PLATFORM) and 24 - MULTIPORT FUEL INJECTION (MFI) for 2.0 LITER 4-CYL. 2V GENERIC SCAN TOOL, ENGINE CODE(S): AEG (A4 PLATFORM) .
Install intake hose - 1 -.
Connect intake hose - 1 - , connector - 2 - and hose - 3 - to Mass Air Flow (MAF) sensor.
Install battery and connect battery Ground (GND) strap → 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

NOTE:

For vehicles equipped with coded anti-theft radio, note code.

Check gear oil in manual transmission with bevel gear transfer case → Gear oil, checking .
Check gear oil specification before refilling → Code letters, aggregate allocation, ratios, capacities .
Bleed clutch system → Clutch system, bleeding .
Adjust shift mechanism → Shift mechanism, adjusting in transmissions with lock bolts (up to transmission manufacture date 180503) .

Install sound insulation.
Install cover for engine.