Transmission, removing and installing (vehicles with 6-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 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: Identifying Engine/Transmission Jack V.A.G 1383 A With Transmission Support 3282 Under Vehicle

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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.
Set transmission to tilt toward left via spindles of transmission support VAS 3282 and rotate upward in bevel gear transfer case area.

Fig 3: Identifying Transmission Support 3282 & Subframe

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Carefully lift transmission and guide past on subframe - arrows -.
Carefully press engine toward front with help of a second technician.

NOTE:

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

Fig 4: Identifying Transmission, Oil Pan, Bevel Gear Transfer Case & Bolting Eyelet

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Guide bevel gear transfer case at bolting eyelet - arrow A - and at oil pan - 2 - as shown - arrow B -.
Rotate transmission - 1 - in area of bevel gear transfer case via spindles of transmission support 3282 downward and guide into flywheel (ring gear for starter).
Align transmission properly to engine and insert.

Fig 5: Identifying Secondary Air Injection Pump Bracket, Engine & Connecting Bolt

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Install top engine/transmission connecting bolt - arrow A - and tighten to specified torque.
Bolt bracket - 1 - for Secondary Air Injection (AIR) pump to engine - arrows - → 26 - EXHAUST SYSTEM, EMISSION CONTROLS .
Install lower intermediate plate.
Install bolts for engine/transmission mount at bottom and tighten to specified torque.

Carefully lift engine with transmission. To do so, turn spindles on engine support bridge V.A.G 10-222A.

Fig 6: Transmission Left Mount

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

NOTE:

Use step ladder VAS 5085 or equivalent 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 .

NOTE:

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

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

NOTE:

Install engine/transmission bearing free of tension → 10 - ENGINE - ASSEMBLY .

Bolt power steering reservoir to engine mount.

Fig 10: Identifying Bevel Gear Transfer Case Bolt

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Install bolt above bevel gear transfer case - arrow - and tighten to specified torque.

Fig 11: Identifying Engine & Bevel Gear Transfer Case Bolts

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Bolt on transmission carrier for bevel gear transfer case to engine and bevel gear transfer case - arrows -.
Press engine/transmission assembly to bulkhead; while doing so, carefully guide pin of bevel gear transfer case into flange/driveshaft.

Fig 12: 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 13: 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 specified torque.
Install front exhaust pipe to exhaust manifold → 26 - EXHAUST SYSTEM, EMISSION CONTROLS .

Fig 14: Identifying Pendulum Support & Bolts

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Install pendulum support - arrows A - and - arrows B - using new bolts → 40 FRONT SUSPENSION .
Install drive axles on transmission → 40 FRONT SUSPENSION .
Install shielding plate for drive axle on right side.
Install radiator coolant fan and auxiliary coolant fan, if installed → 19 - ENGINE - COOLING SYSTEM .

Install double catalytic converter and assemble exhaust system → 26 - EXHAUST SYSTEM, EMISSION CONTROLS .
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.
Install bolts for engine/transmission mount at top and tighten to specified torque.

Fig 15: 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.

Fig 16: Identifying Speedometer Sensor Connector

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Connect connector to Speedometer Vehicle Speed Sensor (VSS) - arrow -.

Fig 17: 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 18: 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 19: Identifying Power Steering Line, Locking Washer, Actuator Lever, Transmission Shift Lever & Nut

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

Fig 20: Identifying Support Bracket At Transmission

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Install cable mounting bracket on transmission and tighten bolts - arrows - to specified torque. Press in hose line at cable mounting bracket if necessary.
Connect shift cable and selector cable to corresponding cable locking mechanisms.
Install battery holder → 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Fig 21: Identifying Air Cleaner Housing & Components

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Install complete air filter housing by tightening bolts - 4 - and - 5 -.
Install intake hose - 1 -.
Connect intake hose - 1 - , connector - 2 - and hose - 3 - to Mass Air Flow (MAF) sensor → 24 - MULTIPORT FUEL INJECTION (MFI) .
Install battery → 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Fig 22: Identifying Hoses & Bracket for Cooling Fluid Line Below Plenum Chamber

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Connect hose - 1 - for crankcase ventilation on cylinder head cover.
Connect hose - 2 - for EVAP canister.
Press bracket for cooling fluid line at bottom to plenum chamber at pins - arrows -.
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.