Audi Workshop Service and Repair Manuals

Install in reverse sequence; note the following points:

Notes:

• ◆ When performing repairs, renew seals, gaskets, self-locking nuts and bolts which have a specified tightening angle.
• ◆ Secure all hose connections with hose clamps of the same type as those fitted at the factory.

=> Parts catalogue

• ‒ Check whether the dowel sleeves for centralising engine/gearbox are in the cylinder block, install if necessary.

• ‒ → Engage intermediate plate on sealing flange, and press onto dowel sleeves -arrows-.
• ‒ Make sure that clutch plate is properly centred.
• ‒ Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease G 000 100 to the splines.

Note:

It must be possible to slide clutch plate easily back and forth on input shaft.

• ‒ Check clutch release bearing (with hydraulic actuator) for wear, renew if necessary.
• ‒ Lift the gearbox carefully and move it to the installation position with gearbox support 3282.

• ‒ → Push the gearbox over the engine flywheel at the front side first -arrow 1-, and then at the rear side -arrow 2-.
• ‒ Secure gearbox to engine.

Notes:

• ◆ The tightening torques listed on this page apply only to lightly greased, oiled, phosphated, or black-finished nuts and bolts.
• ◆ Additional lubricant such as engine or gearbox oil may be used, but do not use graphite lubricant.
• ◆ Do not use degreased parts.
• ◆ Tolerance for tightening torques is ±15%.

Tightening torques

→ Engine/gearbox mountings

A: centering sleeves

• ‒ → Slide in cover plate -2- so that bottom lug engages on cylinder block, and secure at the top with bolt -1-.

Note:

Shown in illustration with gearbox removed.

• ‒ Remove gearbox support 3282, engine support device 3300 A and support T10036.

• ‒ → Use the left spindle to lift engine/gearbox assembly into installation position.

• ‒ Use new bolts for securing.

• ‒ → Install gearbox bracket on gearbox with bolts -1- (40 Nm + 90°).

• ‒ Use new bolts for securing.

• ‒ → Bolt pendulum support onto gearbox -arrows B-
  (40 Nm +1/4turn = 90°).
• ‒ Then bolt pendulum support onto subframe -arrow A-
  (20 Nm +1/4turn = 90°).
• ‒ Install exhaust system and align stress-free:

=> 4-Cylinder TDI®engine; Repair group 26; Removing and installing parts of exhaust system; Stress-free alignment of exhaust system - vehicles with front-wheel drive

• ‒ Bolt drive shafts to gearbox
  (M10 Bolts; 77 Nm)
• ‒ Fit right drive shaft guard (35 Nm).

The remaining installation steps are carried out in the reverse sequence.

• ‒ Attach selector cables to gearbox and adjust=>Page34-20.
• ‒ Bleed clutch system=>Page 30-20.

• ‒ Electrical connections and routing:

=> Current flow diagrams, Electrical fault finding and Fitting locations binder

Note:

After connecting battery, activate the electrical equipment (radio, clock, electric window lifters) as described in the owner's manual.

Tightening torques