Removal And Installation: Transmission: Installing
Refer to "Removing" to get a list of the special tools needed. Refer to REMOVING .
Replace the self-locking nuts and bolts.
Replace bolts that were tightened to a torque angle.
Install any cable ties that were loosened or cut off during removal at their same location.
Clean the input shaft splines and (on a used clutch disc) the hub splines. Remove any corrosion and apply a very thin coating of grease for clutch plate splines G 000 100 on the splines. Then move the clutch disc back and forth on the input shaft until the hub moves freely on the shaft. Excess grease must be removed.
-- If the transmission is replaced, transfer the transmission shift lever and the relay lever.
-- Clean any locking compound residue from all threaded holes using a tap.
-- Check whether there are alignment sleeves for the engine/transmission in the cylinder block; install if necessary.
If the alignment sleeves are missing, it will be difficult to shift, there will be clutch problems and the transmission may make noises (loose rattling).
-- Make sure the intermediate plate is engaged on the sealing flange and pushed onto the alignment sleeves -arrows-.
-- Check the release bearing for wear. If necessary, replace the slave cylinder and the release bearing. Refer to SLAVE CYLINDER WITH RELEASE BEARING .
-- Install the bracket T10346 with the bolt -1- in the left threaded hole in the subframe.
-1- = M6 x 20 collar bolt
-- Install the engine support Device 3300 A to the bracket T10346.
-- Place a cloth between engine support Device 3300 A and the oil pan.
-- Push the engine forward using the spindle on the engine support Device 3300 A. Note the following when doing this:
- The Air Conditioning (A/C) compressor must not touch the refrigerant line -1- -arrow-.
- The generator must not touch the refrigerant line.
- The pressure pipe must not touch the radiator.
To install the transmission, the transmission Support 3282 must be equipped the adjustment Plate 3282/33.
-- Align the arms of the transmission support so that they match up with the holes in the adjustment plate.
-- Install the support elements -A- as illustrated on the adjustment plate.
-- Install the pins 3282/29 in place on the adjustment plate -C-.
-- Place the transmission on the engine/transmission jack V.A.G 1383 A.
-- Align the adjustment plate so that it is parallel to the transmission.
-- Install the Pin 3282/29 into the hole on the transmission for the pendulum support bolt.
-- Install the adapter VW 771/40 in the threaded hole in the transmission housing as illustrated.
-- Secure the transmission on the transmission Support 3282 with an M10 x 20 bolt -A-.
The arm -B- must be flush with the guide on the transmission Support 3282 -arrow-.
-- Place the engine/transmission jack V.A.G 1383 A under the vehicle. The arrow points in the direction of travel.
Pay attention to the lines when installing the transmission.
-- Lift the transmission carefully.
-- Now, turn the transmission upward near the rear differential and downward near the 6th gear using the transmission Support 3282 spindles.
-- Guide the transmission and differential -A- over the subframe.
- The right flange shaft must be guided past the flywheel -arrow 2- ; pay attention to the intermediate plate -arrow 1-.
-- The right flange shaft -1- must be guided over the bolt flange on the engine -2-.
-- Change the position of the transmission using the transmission Support 3282 spindles so that it does not come in contact with the longitudinal member -arrows-.
-- Turn the transmission into its installed position using the spindles on the transmission Support 3282.
-- Line up the transmission and the engine and install it.
-- Install the engine/transmission bolt -C- and tighten it to specification. Refer to TIGHTENING SPECIFICATIONS .
-- Install the lower engine/transmission bolts and tighten them to specification. Refer to TIGHTENING SPECIFICATIONS .
-- Remove the engine support Device 3300 A and the bracket T10346.
-- Install the engine/transmission bolt -arrow- and tighten it to specification. Refer to TIGHTENING SPECIFICATIONS .
-- Remove the transmission Support 3282 after the transmission is bolted to the engine at the bottom.
-- Install the upper engine/transmission bolts and tighten them to specification. Refer to TIGHTENING SPECIFICATIONS .
-- Attach the transmission shift lever to the gear shift shaft tighten the nut to specification. Refer to Figure and see "Nut" in item: 17.
-- Install the relay lever with the cable retainer. Refer to PLASTIC RELAY LEVER .
-- Install the engine mount bracket -1- to the transmission with new bolts -arrows- and tighten them to specification. Refer to TIGHTENING SPECIFICATIONS .
-- Align the engine/transmission in its installed position. Lift it until the engine mount bracket -1- is in complete contact with the transmission mount -2-.
-- Install the new engine mount to engine mount bracket bolts -arrows- and tighten them to specification. Refer to TIGHTENING SPECIFICATIONS .
Install the transmission mount free of tension. Refer to Description and Operation .
Only remove the engine support bridge 10-222 A when all the transmission mount bolts are tightened to specification.
-- Install the flywheel cover plate -A- (if equipped). Refer to TIGHTENING SPECIFICATIONS .
There are threaded inserts (for example a "HeliCoil") in the pendulum support holes in the transmission.
How to recognize: there is a collar on the 1st thread -arrow-.
For the correct bolts and tightening specifications, refer to SPECIFICATIONS .
-- Install the pendulum support. Refer to INSTALLING .
-- Install the drive axles. Refer to Removal and Installation .
-- Install the drive axle heat shield and bolts -arrow-, if equipped. Refer to DRIVE AXLE HEAT SHIELDS .
-- Install the left coupling rod. Refer to SUBFRAME, STABILIZER BAR AND CONTROL ARM ASSEMBLY OVERVIEW .
-- Install the left front level control system sensor -G78- to the control arm, if equipped. Refer to LEFT FRONT LEVEL CONTROL SYSTEM SENSOR .
-- Connect the connector -1- to the oil level thermal sensor -G266-.
-- Assemble the exhaust system and attach the suspended mount to the subframe. Refer to SUBFRAME, LOWERING .
-- Install the fan shroud -arrow- and fans. Refer to Removal and Installation .
-- Install the charge air pipe to the engine. Refer to Description and Operation .
-- Install the left charge air hose and tighten the clamps -arrows 1 and 2-. Refer to Description and Operation .
-- Install the right charge air hose to the charge air cooler. Refer to Description and Operation .
-- Install the starter and tighten the lower bolt. Refer to Removal and Installation .
-- Attach the bracket for the lines to the lower starter bolt.
-- Install the top bolt for the starter and attach the connectors and the cables to the starter. Refer to "Starter" in Removal and Installation .
-- Install the ground strap -1- and nut to the upper starter bolt.
-- Connect the connector -2- to the backup lamp switch -F4-.
-- Push the hose/line assembly or plastic line -A- into the breather/slave cylinder up to the stop and push the circlip -arrow- downward.
-- Pull on the line to make sure it is secure.
-- Remove the hose clamps up to 25 mm Dia. 3094 from the hose.
-- After removing the hose clamps up to 25 mm Dia. 3094, bring the hose back to its original shape.
-- Bleed the clutch system. Refer to CLUTCH SYSTEM, BLEEDING .
-- Make sure the vacuum hose for the brake system is installed correctly. Refer to Description and Operation .
-- Install the cable bracket to the transmission and tighten the bolts/nut -arrows- to specification, see "Bolt" in item: 6 and "Nut" in item: 10.
-- Insert the selector cable into the cable retainer.
-- Apply a small amount of grease G 000 450 02 to the pin -arrow- on the transmission shift lever -2-.
-- Replace the lock washer -1- after every disassembly.
-- Adjust the shift mechanism. Refer to SHIFT MECHANISM, ADJUSTING .
-- Install the battery tray, the battery and the cover. Refer to Removal and Installation .
-- Install the air filter housing, if it was removed earlier. .
-- Install the engine cover, if necessary.
-- Connect the battery and then complete the steps after connecting the battery. Refer to Removal and Installation .
-- Check the transmission fluid level. Refer to TRANSMISSION FLUID, CHECKING .
-- Install the lower section of the left front wheel housing liner. Refer to Removal and Installation .
-- Install the noise insulation. Refer to Description and Operation .
-- Check the headlamp adjustment if the vehicle has a left front level control system sensor. Refer to Diagnosis and Testing .
Refer to "Removing" to get a list of the special tools needed. Refer to REMOVING .
Replace the self-locking nuts and bolts.
Replace bolts that were tightened to a torque angle.
Install any cable ties that were loosened or cut off during removal at their same location.
Clean the input shaft splines and (on a used clutch disc) the hub splines, remove corrosion and apply a very thin coating of grease for clutch plate splines G 000 100 to the splines. Then move the clutch disc back and forth on the input shaft until the hub moves freely on the shaft. Excess grease must be removed.
-- If the transmission is replaced, transfer the transmission shift lever and the relay lever.
-- Clean any locking compound residue from all threaded holes using a tap.
-- Check whether there are centering sleeves for the engine/transmission in the cylinder block; install if necessary.
If the alignment sleeves are missing, it will be difficult to shift, there will be clutch problems and the transmission may make noises (loose rattling).
-- Make sure the intermediate plate is engaged on the sealing flange and pushed onto the alignment sleeves -arrows-.
-- Check the release bearing for wear. If necessary, replace the slave cylinder and the release bearing. Refer to SLAVE CYLINDER WITH RELEASE BEARING .
-- Install the bracket T10346 with the bolt -1- in the left threaded hole in the subframe.
-- Install the bracket T10346 in the same angled position as the engine.
-1- = M6 x 20 collar bolt
-- Install the engine support Device 3300 A to the bracket T10346.
-- Push the engine forward using the spindle on the engine support Device 3300 A. Note the following when doing this:
- The Air Conditioning (A/C) compressor must not touch the refrigerant line -1- -arrow-.
- The generator must not touch the refrigerant line.
- The pressure pipe must not touch the radiator.
To install the transmission, the transmission Support 3282 must be equipped with the adjustment Plate 3282/33.
-- Align the arms of the transmission support so that they match up with the holes in the adjustment plate.
-- Install the support elements -A- as illustrated on the adjustment plate.
-- Install the pins 3282/29 in place on the adjustment plate -C-.
-- Place the transmission on the engine/transmission jack V.A.G 1383 A.
-- Align the adjustment plate so that it is parallel to the transmission.
-- Install the Pin 3282/29 into the hole on the transmission for the pendulum support bolt.
-- Install the adapter VW 771/40 in the threaded hole in the transmission housing as illustrated.
-- Secure the transmission on the transmission Support 3282 with an M10 x 20 bolt -A-.
The arm -B- must be flush with the guide on the transmission Support 3282 -arrow-.
-- Place the engine/transmission jack V.A.G 1383 A under the vehicle. The arrow points in the direction of travel.
Pay attention to the lines when installing the transmission.
-- Using the spindles on the transmission Support 3282, adjust the transmission so that the differential area is rotated in the -direction of the arrow- upward.
-- Lift the transmission carefully.
-- Guide the transmission and differential -A- over the subframe.
-- Pay attention to the longitudinal member -arrows-.
-- Move the transmission toward the rear to the subframe.
- After that, the right flange shaft -1- must be guided past the flywheel and the cutout -arrow- in the intermediate plate.
-- Turn the transmission into its installed position using the spindles on the transmission Support 3282.
-- Line up the transmission and the engine and install it.
-- Install the engine/transmission bolt -C- and tighten it to specification. Refer to TIGHTENING SPECIFICATIONS .
-- Install the engine/transmission bolt -arrow- and tighten it to specification. Refer to TIGHTENING SPECIFICATIONS .
-- Remove the engine support device 3300 A and the bracket T10346.
-- Install the lower engine/transmission bolts and tighten them to specification. Refer to TIGHTENING SPECIFICATIONS .
-- Remove the transmission Support 3282 after the transmission is bolted to the engine at the bottom.
-- Install the upper engine/transmission bolts and tighten them to specification. Refer to TIGHTENING SPECIFICATIONS .
-- Attach the transmission shift lever to the gear shift shaft and tighten the nut to specification, refer to Figure and see "Nut" in item: 17.
-- Install the relay lever with the cable retainer. Refer to PLASTIC RELAY LEVER .
-- Install the transmission mount bracket -1- with new bolts -arrows- to the transmission and tighten them to specification. Refer to TIGHTENING SPECIFICATIONS .
-- Align the engine/transmission in its installed position. Lift it until the transmission mount bracket -1- is in complete contact with the transmission mount -2-.
-- Install the new transmission mount to transmission mount bracket bolts -arrows- and tighten them to specification. Refer to TIGHTENING SPECIFICATIONS .
Install the transmission mount free of tension. Refer to [For engine(s) BPY] General Information .
Only remove the engine support bridge 10-222 A when all the transmission mount bolts are tightened to the specification.
-- Install the flywheel cover plate -A- (if equipped). Refer to TIGHTENING SPECIFICATIONS .
There are threaded inserts (for example a "HeliCoil") in the pendulum support bolt holes in the transmission.
How to recognize: there is a collar on the first thread -arrow-.
For the correct bolts and tightening specifications, refer to SPECIFICATIONS .
-- Install the pendulum support. Refer to SUBFRAME BONDED RUBBER BUSHINGS .
-- Install the exhaust system. Refer to EXHAUST SYSTEM, INSTALLING , or REMOVAL AND INSTALLATION .
-- Install the drive axles. Refer to Removal and Installation .
-- Install the drive axle heat shield and bolts -arrows-, if equipped. Refer to DRIVE AXLE HEAT SHIELDS .
-- Install the left coupling rod. Refer to RIGHT DRIVE AXLE WITH MOUNTED CV JOINT .
-- Install the left front level control system sensor -G78- to the control arm, if equipped. Refer to Removal and Installation .
-- Install the fan shroud -arrow- and fans. Refer to FAN SHROUD .
-- Install the charge air hose and clamps -arrows 1 and 2- and then connect the charge air pipe to the engine. Refer to CHARGE AIR HOSE AND PIPE, DISCONNECTING AND CONNECTING .
-- Install the starter and tighten the lower bolt. Refer to Removal and Installation .
-- Attach the bracket for the lines to the lower starter bolt.
-- Install the top bolt on the starter and attach the connectors and the cables to the starter. Refer to "Starter" in Removal and Installation .
-- Install the ground strap -1- and nut to the top starter bolt.
-- Connect the connector -2- to the backup lamp switch -F4-.
-- Push the hose/line assembly or plastic line -A- into the breather/slave cylinder up to the stop and push the circlip -arrow- downward.
-- Pull on the line to make sure it is secure.
-- Remove the hose clamps up to 25 mm Dia. 3094 from the hose.
-- After removing the hose clamps up to 25 mm Dia. 3094, bring the hose back to its original shape.
-- Bleed the clutch system. Refer to CLUTCH SYSTEM, BLEEDING .
-- Make sure the vacuum hose for the brake system is installed correctly. Refer to Description and Operation .
-- Install the cable bracket to the transmission and tighten the bolts/nut -arrows- to specification, see "Bolt" in item: 6 and "Nut" in item: 10.
-- Insert the selector cable into the cable retainer.
-- Apply a small amount of grease G 000 450 02 to the pin -arrow- on the transmission shift lever -2-.
-- Replace the lock washer -1- after every disassembly.
-- Adjust the shift mechanism. Refer to SHIFT MECHANISM, ADJUSTING .
-- Install the battery tray, the battery and the battery cover. Refer to Removal and Installation .
-- Install the air filter housing, if it was removed earlier. Refer to ENGINE COVER/UPPER AIR FILTER HOUSING , or AIR FILTER HOUSING .
-- Install the plenum chamber cover and seal. Refer to "Flush Bonded Windows" in Description and Operation .
-- Attach the foam pieces to the upper edges on the left and right fenders. Refer to Description and Operation .
-- Install the engine cover if necessary.
-- Connect the battery and then complete the steps after connecting the battery. Refer to Removal and Installation .
-- Check the transmission fluid level. Refer to TRANSMISSION FLUID, CHECKING .
-- Install the lower section of the left front wheel housing liner. Refer to Removal and Installation .
-- Install the noise insulation. Refer to Description and Operation .
-- Check the headlamp adjustment if the vehicle has a left front level control system sensor. Refer to Diagnosis and Testing .