Volkswagen Workshop Service and Repair Manuals

Installing gearbox   Note t  Refer to procedure „Removing gearbox“ for required special tools → Chapter. t  Renew self-locking nuts and bolts. t  Renew bolts which must be tightened further to a torque angle. t  All cable ties which were opened or cut during removal must be renewed at the same points. t  Clean input shaft splines and, on used clutch plate, hub splines. Remove corrosion and apply only a very thin coat of clutch plate spline grease -G 000 100- to splines. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease. –  If the gearbox is to be renewed, the gearbox selector lever and relay lever must be transferred to the new gearbox. –  All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap. –  Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary. If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

–  Ensure that intermediate plate is hooked into sealing flange and pushed onto dowel sleeves -arrows-. –  Check release bearing for wear. If necessary, renew slave cylinder with release bearing → Chapter. –  Attach bracket -T10346- with bolt -1- to left threaded hole in subframe. –  In the process, position bracket -T10346- at the same angle as the engine. -1- = Flange bolt M6 x 20.

–  Secure engine support -3300 A- to bracket -T10346-.

–  Press engine forwards using spindle of engine support -3300 A-. In the process, observe the following points in particular: l  The air conditioning compressor -2- must not contact -arrow- the refrigerant line -1-. l  The alternator must not contact the refrigerant line. l  The pressure pipe must not contact the radiator.

To install gearbox „02Q“, set up gearbox support -3282- with adjustment plate -3282/33-. –  Align arms of gearbox support according to holes in adjustment plate. –  Attach support elements-A- to adjustment plate as illustrated. –  Screw in pin -3282/29- instead of support element-C-. –  Place gearbox on engine and gearbox jack -V.A.G 1383 A-. –  Align adjustment plate and gearbox parallel to one another. –  Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

–  Secure adapter -VW 771/40- in threaded hole of gearbox housing as shown in figure. –  Secure gearbox to gearbox support -3282- using bolt (M10x20) -A-. Pin -B- must lie flush with guide from gearbox support -3282- at bottom -arrow-. –  Position engine and gearbox jack -V.A.G 1383 A- under vehicle. Arrow on adjustment plate points in direction of vehicle travel.   Note Be careful of all lines when installing gearbox.

–  Now turn gearbox in area of differential -in direction of arrow- using spindles of gearbox support -3282-. –  Then carefully raise gearbox.

–  Guide gearbox with differential -A- over subframe.

–  Observe longitudinal member -arrows-.

–  Guide gearbox with differential over subframe -A--in direction of arrow-. –  Swing rear of gearbox towards subframe. l  Then the right flange shaft -1- must be guided past the flywheel and the notch -arrow- in the intermediate plate. –  Then turn gearbox to installation position via spindles of gearbox support -3282-. –  Align gearbox on engine dowel sleeves and join.

–  Screw in engine/gearbox connecting bolt -C- and tighten to specified torque → Chapter. –  Screw in engine/gearbox connecting bolt -arrow- and tighten to specified torque → Chapter.

–  Remove engine support -3300 A- and bracket -T10346-. –  Screw in lower engine/gearbox securing bolts and tighten to specified torque → Chapter. –  After bottom of gearbox and engine are bolted together, remove gearbox support -3282- from gearbox. –  Insert upper engine/gearbox securing bolts and tighten to torque specification → Chapter. –  Attach gearbox selector lever to selector shaft of gearbox → Fig. and tighten hexagon nut to specified torque → Item. –  Install relay lever together with cable end-piece → Chapter.

–  Install bracket -1- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque → Chapter.

–  Align engine and gearbox in installation position. To do this, raise sufficiently so that bracket -1- completely contacts left assembly mounting -2-. –  Screw new hexagon bolts -arrows- for left assembly mounting -2- into bracket -1- and tighten to specified torque → Chapter.   Note Install engine and gearbox mounting free of tension → Rep. gr.10.   WARNING Do not remove support bracket -10-222 A- until all bolts securing the assembly mounting have been tightened to specified torque.

–  If small cover plate -A- for flywheel is present, install it -arrows- → Chapter.   Note t  There are threaded inserts, e.g. „HeliCoil“ in the bolting holes for the pendulum support.

t  Identification: shoulder along beginning of thread -arrow-. t  Ensure that the correct securing bolts and torque specifications are used. → Running gear, axles, steering; Rep. gr.40

–  Install pendulum support → Running gear, axles, steering; Rep. gr.40. –  Reassemble exhaust system → Rep. gr.26.

–  Then install drive shafts → Running gear, axles, steering; Rep. gr.40. –  Install drive shaft heat shield, if present -arrows- → Running gear, axles, steering; Rep. gr.40. –  Install left coupling rod. → Running gear, axles, steering; Rep. gr.40

–  If featured, bolt front vehicle level sender -G78- to transverse link → Rep. gr.40.

–  Attach connector -1- to oil level and oil temperature sender -G266-.

–  Install cowling -arrow- together with radiator fans. → Rep. gr.19

–  Fit charge air hoses -arrow 1- and -arrow 2- and charge air pipe on engine → Rep. gr.21. –  Then install starter and secure with lower bolt → Electrical system; Rep. gr.27. –  Secure wiring retainer to lower starter bolt. –  Install upper starter bolt; attach connector and wiring to starter → Electrical system; Rep. gr.27.

–  Attach earth strap -1- to upper starter bolt. –  Push connector -2- onto reversing light switch -F4-.

–  Push pipe/hose line or pipe line -A- to stop into slave cylinder breather and press down clip -arrow-. –  Test line by tugging on it. –  Remove hose clamp -3094- from pipe/hose line or supply hose. –  After removing hose clamp -3094-, return supply hose to its original shape, if necessary. –  Bleed clutch system → Chapter. –  Check for correct installation position of vacuum hose for brake system, install vacuum hose if necessary → Rep. gr.47.

–  Bolt selector cable support brackets to gearbox and tighten bolts and nuts -arrows- to specified torque → Item and → Item.

–  Insert gate selector cable in cable end-piece. –  Spread a small amount of grease on pin -arrow- of gearbox selector lever -2-. Allocate grease using → Electronic parts catalogue (ETKA). –  Renew securing clip -1- each time it is removed. –  Adjust selector mechanism → Chapter. –  Install battery tray and battery → Electrical system; Rep. gr.27. –  If removed, install complete air filter housing → Rep. gr.23 or → Rep. gr.24 –  Install plenum chamber cover with seal. → Glazing; Rep. gr.64 –  Set both foam pieces on upper edge of left and right wings → Body, front; Rep. gr.50. –  If necessary, install engine cover. –  Connect battery and follow procedure after connecting battery → Electrical system; Rep. gr.27. –  Check gear oil → Chapter. –  Install lower part of front left wheel housing liner → General body repairs, exterior; Rep. gr.66. –  Install noise insulation → General body repairs, exterior; Rep. gr.50. –  For vehicles with front vehicle level sender -G78-, check headlight adjustment → Electrical system; Rep. gr.94.