Audi Workshop Service and Repair Manuals

Installing gearbox on vehicles with 4-cylinder or 6-cylinder engine Installation is carried out in reverse sequence; note the following: –  Use a thread tap to remove any remaining locking fluid from all threaded holes which will accommodate self-locking bolts. –  Always renew self-locking bolts and nuts. –  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 for clutch plate splines -G 000 100- to the splines. Do not grease guide sleeve. It should be possible to push the clutch plate back and forth slightly on the input shaft.

–  Check clutch release bearing for wear and renew if necessary → Chapter. –  If plastic ring -arrows- has come loose, service release bearing as required → Fig.. –  Check that dowel sleeves for centralising engine/gearbox are in the cylinder block, install if necessary. –  Place intermediate plate on dowel sleeves at engine flange. –  Before installing gearbox, tie electrical wires and brackets off to one side so that they are not trapped between the engine and the gearbox.

–  Lightly lubricate surface where plunger and clutch release lever make contact -arrow B- using grease -Z 381 351 TE-. –  Raise gearbox far enough to be able to install clutch slave cylinder with bracket for pipe/hose assembly. –  Guide slave cylinder -1- into opening in gearbox housing keeping it as straight as possible (without tilting plunger -arrow A-) and insert in recess -arrow B- on clutch release lever -3-.   Note If the slave cylinder -1- is inserted at an angle, there is a danger that the plunger -arrow A- will be guided past the clutch release lever -3-.

–  Secure clutch slave cylinder with new bolt -arrow-.   Caution After installing the slave cylinder press the clutch pedal carefully. If you feel an unusually strong point of resistance when depressing the clutch pedal, you must not press it down further. The plunger of the slave cylinder is likely to have been guided past the clutch release lever. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N. –  Insert gearbox, making sure there is sufficient clearance to drive shafts.

–  Install engine/gearbox securing bolts -arrow A- and -arrow B-.

–  Install starter → Rep. Gr.27.

–  Carefully lower gearbox a short distance using engine and gearbox jack -V.A.G 1383 A-. –  If possible, tighten upper engine/gearbox securing bolts -arrows 1- and -arrows 2-.

–  If fitted, secure all electrical wiring to gearbox again -arrows A ... C-.

–  If fitted, install engine speed sender -G28- on left side of gearbox.

–  Install gearbox selector lever and tighten nut -arrow-.

–  Install push rod -1-; to do so, tighten hexagon socket head bolt. –  Secure connecting rod -2- for selector rod.

–  Attach electrical connector -arrow- for reversing light switch -F4- on gearbox (right side).

–  Lift gearbox again using engine and gearbox jack -V.A.G 1383 A-. –  Attach tunnel cross member to body with bolts -2- and -3- (tighten hand-tight only).   Note Renew bolts -3-. –  Bolt tunnel cross member onto gearbox mounting -4- → Rep. Gr.40. –  Carefully lower engine and gearbox jack -V.A.G 1383 A- and move it aside. –  Attach drive shafts -1- to flange shafts → Rep. Gr.40.

Cabriolet vehicles with 4-cylinder engine: –  Lift engine slightly using spindles.

–  Tighten the bottom engine/gearbox securing bolts -arrows-. –  Lower engine back down.

–  Secure torque reaction support -arrows-.

–  Tighten nuts -3- for engine mountings → Rep. Gr.10. –  Secure anti-roll bar -2- with nuts -1- → Rep. Gr.40.

Vehicles with 6-cylinder petrol engine: l  Weight of engine is partly taken up with support bracket -10 - 222 A- → Anchor. –  First remove front bolts -2- and -3- on subframe (left and right). Then remove bolts -1-. –  Lower subframe at the front.

–  Tighten three bottom engine/gearbox securing bolts -arrows-.

–  Renew the front subframe bolts -1-, -2- and -3- on both sides of the vehicle.

Before tightening subframe, it must be aligned with body using locating pins -3393-. l  Hole -1-, hole -2- in subframe and hole -3- in aluminium bracket must be in alignment on both sides.   Note This alignment can only replace a subsequent wheel alignment if holes -1- and -2- coincided before the repair work was carried out. –  Secure subframe → Rep. Gr.40.

–  Tighten nuts -1- for engine mountings → Rep. Gr.10. Continued for all vehicles: –  Secure tunnel cross member → Rep. Gr.40. –  Install exhaust system and align free of stress → Rep. Gr.26. –  Check selector mechanism setting and adjust if necessary → Chapter. –  Check gear oil level in gearbox → Chapter. –  Follow the steps required after connecting the battery → Rep. Gr.27. –  Check and adjust wheel alignment if necessary → Rep. Gr.44. t  Wheel alignment is not necessary if subframe was located in relation to body using locating pins -3393- prior to dismantling and assembly of subframe (before tightening bolts). t  Wheel alignment must, however, be carried out if the subframe was not located in relation to the body using locating pins -3393- or if it was not possible to fully insert the two pins into the holes. Tightening torques   Note t  Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts. t  Additional lubricant such as engine or gearbox oil may be used, but do not use graphite lubricant. t  Do not use parts which have been degreased. t  Tolerance for tightening torques ±15%.

Engine/gearbox attachment (2.0 ltr. petrol engine)

Item	Bolt	Nm
1 1)	M12 x 75	65
2 1)	M12 x 90	65
3 2)	M12 x 75	65
4, 6	M12 x 90	65
5 2)	M12 x 110	65
7 3)	M10 x 50	45
8, 9, 10	M10 x 45	45
11 4)	M12 x 110	65
A	Dowel sleeves for centralising
1) Secures starter to gearbox 2) With bracket for wiring harness 3) Hammer head bolt with nut 4) With nut

Engine/gearbox attachment (1.9 ltr. TDI engine)

Item	Bolt	Nm
1 1)	M12 x 80	65
2 1)	M12 x 95	65
3 2)	M12 x 80	65
4, 6	M12 x 95	65
5 2)	M12 x 110	65
7 3)	M10 x 50	45
8, 9, 10	M10 x 45	45
11 4)	M12 x 110	65
A	Dowel sleeves for centralising
1) Secures starter to gearbox 2) With bracket for wiring harness 3) Hammer head bolt with nut 4) With nut

Engine/gearbox attachment (2.0 ltr. TDI engine)

Item	Bolt	Nm
1 1)	M12 x 105	65
2 2)	M12 x 80	65
3 2)	M12 x 90	65
4 3)	M12 x 80	65
5, 7	M12 x 95	65
6 3)	M12 x 105	65
8 4)	M10 x 50	45
9, 10, 11	M10 x 45	45
A	Dowel sleeves for centralising
1) With nut 2) Secures starter to gearbox 3) With bracket for wiring harness 4) Hammer head bolt with nut

Engine/gearbox attachment (6-cylinder 2.4 ltr. petrol engine)

Item	Bolt	Nm
1, 9, 10, 11	M10 x 60	45
2 1)	M10 x 150	65
3	M12 x 130	65
4 … 6	M12 x 80	65
7	M12 x 100	65
8	M12 x 90	65
A	Dowel sleeves for centralising
1) Property class 10.9

Engine/gearbox attachment (6-cylinder 3.0 ltr. petrol engine)

Item	Bolt	Nm
1, 10, 11	M10 x 60	45
2 1)2)	M10 x 150	65
3 1)	M12 x 130	65
4	M12 x 85	65
5, 6	M12 x 90	65
7	M10 x 100	45
8	M12 x 95	65
9 3)	M10 x 60	45
A	Dowel sleeves for centralising
1) Secures starter to gearbox 2) Property class 10.9 3) Hammer head bolt with nut

Component	Nm
Slave cylinder to gearbox	23 1)
Gearbox selector lever to gearbox	20
Push rod to gearbox	40
Connecting rod for selector rod to gearbox	20
Gearbox mounting to gearbox	23
Tunnel cross member to gearbox mounting	23
Heat shields above drive shafts to gearbox	23
Engine mounting to engine support	23
Torque reaction support to engine (Cabriolet only)	30 + 90° 1)
Bracket for noise insulation to subframe	10
1) Renew bolt