Transmission, Installing, 2.0L - 155 Kw - Gasoline Engine
Refer to TRANSMISSION, REMOVING, 2.0L - 155 KW - GASOLINE ENGINE for a list of the special tools needed.
Install in the reverse order of removal while noting the following:
Always replace the needle bearing -arrow- after separating the engine and transmission.
If the needle bearing in the crankshaft is damaged, the gears will no longer shift correctly.
-- Replace the needle bearing in the crankshaft. Refer to CRANKSHAFT NEEDLE BEARING, REPLACING .
-- Transmission pins (not splines) on the drive axle must be lightly lubricated.
-- Make sure both alignment sleeves between the engine and the transmission are correctly seated.
-- Make sure the intermediate plate fits correctly.
-- Guide the selector lever cable into the cable bracket as soon as possible.
Do not grease the selector lever cable.
-- Carefully raise the transmission using the :VAS6931 and bring it into the installation position using the :3282 .
Guide the Engine and Transmission Together by Hand until the Engine Flange and Transmission Flange Come into Contact with One Another All Around.
If they do not, >>something is incorrect<< !
-- Adjust the transmission mount until the engine and transmission >>are in alignment<<.
-- Turn the crankshaft slightly if necessary.
-- Insert the transmission without pinching any lines.
-- Attach the transmission to the engine. Transmission to engine tightening specifications. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .
Install the left subframe mount as follows:
-- Replace all bolts -1 and 2- for the left subframe mount.
-- Install all new bolts first by hand.
-- Fasten the transmission bracket -A- to the transmission using the bolts -1-.
-- The align the engine/transmission in its installation position. Lift until the transmission bracket is touching the transmission mount completely.
There is a risk of damaging the threads in transmission bracket by inserting the bolts at an angle.
- Before installing the bolts -2-, the transmission bracket and transmission mount support arm must be absolutely parallel to each other. If necessary, lift the back of the transmission using the Engine and Gearbox Jack.
Install the engine/transmission mount free of tension. Refer to SUBFRAME MOUNT [For engine(s) CBPA]SUBFRAME MOUNT [For engine(s) CPPA, CPLA] .
-- Tighten the bolts -2- to the tightening specification. Refer to OVERVIEW - SUBFRAME MOUNT .
Only remove the :10-222A when all the left and right subframe mount bolts are tightened to the tightening specification.
-- Remove the :10-222A .
-- Install the starter. Refer to STARTER .
Connect the connector -A- from the DSG Transmission Mechatronic - J743- as follows.
-- The arrow -D- on the DSG Transmission Mechatronic - J743- -B- must line up with the connector -A- as well as with the tab -C-.
-- Connect the connector -A- carefully all the way and then turn the lock >>clockwise<< in the direction of the -arrow-.
-- Attach the drive axles to the transmission. Refer to DRIVE AXLE .
-- Install the heat shield over the right drive axle. Refer to DRIVE AXLE .
-- Install the subframe with the steering gear. Refer to SUBFRAME .
-- Install the pendulum support with new bolts on the transmission. Refer ASSEMBLY MOUNTS .
-- Selector lever cable lock washers -arrows- must be replaced.
-- Always adjust the selector lever cable. Refer to SELECTOR LEVER CABLE, CHECKING AND ADJUSTING .
-- Check the coolant level and fill if necessary. Refer to COOLANT SYSTEM/COOLANT [For engine(s) CBPA] or COOLANT SYSTEM/COOLANT [For engine(s) CPPA, CPLA] .
-- Assemble the exhaust system and attach the exhaust system bracket to subframe. Refer to EXHAUST PIPES/MUFFLERS [For engine(s) CPPA, CPLA]EXHAUST PIPES/MUFFLERS [For engine(s) CBPA] .
-- Install the plenum chamber cover. Refer to BULKHEAD .
-- Install the bolts -arrows- for the left and right lock carrier retaining brackets to the tightening specification. Refer to LOCK CARRIER .
-- Install the battery tray and the battery. Refer to BATTERY, REMOVING AND INSTALLING .
-- Install the air filter. Refer to AIR FILTER [For engine(s) CBPA] or AIR FILTER [For engine(s) CPPA, CPLA] .
-- Connect the battery and follow the steps after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .
-- Install the engine cover. Refer to ENGINE COVER [For engine(s) CBPA] .
-- Install the left front wheel housing liner. Refer to WHEEL HOUSING LINER .
-- Install the noise insulation. Refer to NOISE INSULATION .
-- Attach the front wheels. Refer to WHEELS AND TIRES .