Audi Workshop Service and Repair Manuals

Installing gearbox on vehicles with 2.0 ltr. TDI engine (common rail)

Tightening torques for engine/gearbox joint

Item	Bolt	Nm
1 ... 2	M12×55 t  With stud M8 t  Renew bolt	80
3 ... 4	M12×165 t  With stud M8	80
5	M10×105 t  Renew bolt	40
6 ... 7	M10×50 t  Renew bolt	40
8	M12×70 t  Installed from engine side t  Renew bolt	80
A	Dowel sleeves for centralising

Other tightening torques

Component		Nm
Small cover plate for flywheel		10
Heat shield for drive shaft (right-side) to cylinder block		25
Earth wire to top starter bolt		23
Bracket for electrical wiring at bottom starter bolt		23
Selector cable support bracket to gearbox		20

Installing gearbox Installation is carried out in reverse sequence; note the following:   Note t  Renew bolts which are tightened by turning through a specified angle. t  Renew self-locking nuts and bolts, and seals, O-rings and gaskets. t  Use thread tap to remove any remaining locking fluid from all threaded holes which will accommodate self-locking bolts. t  Hose connections and air pipes and hoses must be free from oil and grease before fitting. t  Secure all hose connections with the correct hose clips (as original equipment); refer to → Electronic parts catalogue. t  All cable ties which are released or cut open during removal must be fitted in the same position when installing. t  When renewing the gearbox, the gearbox selector lever must be transferred to the new assembly. t  Clean input shaft splines and (in the case of a used clutch plate) also clean the hub splines. Remove corrosion and apply only a very thin coating of grease -G 000 100- to the splines. Then move clutch plate backwards and forwards on input shaft until hub moves freely on shaft. It is important to remove excess grease.

–  Check that dowel sleeves -arrows- for centralising engine/gearbox are in the cylinder block; install if necessary. If the dowel sleeves are not fitted, this will lead to gear-change problems, clutch malfunction and in some cases gearbox noise (gears will make rattling noises). –  Make sure that the intermediate plate is engaged on the sealing flange and fitted on the dowel sleeves -arrows-. –  Check that clutch plate is centralised → Chapter. –  Check release bearing for wear. If necessary, renew slave cylinder with release bearing → Chapter.

–  Raise gearbox carefully and move to installation position using gearbox support -3282-. –  Join gearbox to engine, taking care not to trap wiring or other connections. –  Secure gearbox and starter to engine. Tightening torque → Anchor

–  Remove engine support -3300 A- and support -T10036-.

Metal gate relay lever -1- –  Insert gate relay lever -1- and secure with securing clip -arrow-.

Plastic gate relay lever –  Insert gate relay lever together with cable end-piece. l  Gate relay lever is secured by detent -arrow 1-. l  Ensure that components engage securely. l  Cable end-piece must be behind detent -arrow 2-. Continued for all vehicles

–  Attach gearbox bracket to gearbox with new hexagon bolts -arrows- and tighten to specified torque. Tightening torque → Chapter

–  Align engine/gearbox in installation position. To do so, raise engine/gearbox until gearbox bracket -1- makes full contact with gearbox mounting (left) -2-.   Note Gearbox mounting and gearbox bracket must be parallel to avoid causing damage to thread of gearbox bracket. –  Secure gearbox bracket -1- to gearbox mounting (left) -2- with new hexagon bolts -arrows-. Tightening torque → Chapter   Caution Do not remove support bracket -10-222A- until all bolts securing the left-hand engine/gearbox mounting have been tightened to the specified torque.

–  Fit pendulum support with new bolts -1 … 3- in accordance with installation instructions → Anchor. Tightening torques → Chapter –  Check mountings of engine/gearbox assembly for correct adjustment, and re-adjust if necessary → Engine, mechanics; Rep. Gr.10.

–  Install radiator cowl -arrows- and attach electrical connector -1-.

–  Install air intake hose. Make sure retaining clip -arrow- snaps onto retaining lug -A-.

–  Attach bracket -1-. –  Plug connector -2- onto reversing light switch -F4-. –  Assemble exhaust system and align so it is free of stress → Rep. Gr.26.

–  Install small flywheel cover plate -A-.

Vehicles with flange shaft (right-side): -A- –  Bolt drive shaft (right-side) to gearbox flange shaft -A- → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40.

–  Then fit protective cap for inner right constant velocity joint on engine -arrows-. Continued for all vehicles: –  Bolt drive shaft (left-side) to gearbox flange shaft → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40.

–  Apply a small quantity of brake fluid to new sealing ring -3- and fit on pipe/hose assembly -4-. –  Push pipe/hose assembly -4- into bleeder connection -1- so that retaining clip -2- snaps into place. –  Pull on pipe/hose assembly to check it is secure. –  Remove hose clamp -3094-. –  Bleed clutch system → Chapter.

–  Apply a small quantity of grease -G 000 450 02- to pin -arrow- of gearbox selector lever -1-. –  Push gear selector cable onto pin -arrow- and secure with securing clip -3-. Metal gate relay lever -2- –  Apply a small quantity of grease -G 000 450 02- to pin -arrow- of gate relay lever -2-. –  Push gate selector cable onto pin -arrow- and secure with securing clip -4-. Plastic gate relay lever -2- –  Insert gate selector cable in cable end-piece. Continued for all vehicles –  Adjust selector mechanism → Chapter.

–  Fit earth wire -1-. –  Install battery tray and battery → Electrical system; Rep. Gr.27. –  Install air cleaner housing → Rep. Gr.23. –  Install engine cover panel. –  Check gear oil level in gearbox → Chapter.

–  Install wheel housing liner (left-side). Audi A3 –  Install noise insulation (bottom) -fasteners 1 ... 3-.

Audi A3 Cabriolet –  Install noise insulation frame -arrow- → Rep. Gr.50.

–  Install noise insulation (centre) -1- → Rep. Gr.50.

Continued for all vehicles Secure drive shaft (left-side) with new bolt -2- → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40.   Note Wheels must not be in contact with ground when tightening drive shaft as otherwise wheel bearing could be damaged.