Installing gearbox on vehicles with 1.8 ltr. and 2.0 ltr. FSI turbocharged engine — AUDI

🧭 Before you start

Fits: Audi A3 (8P, 2003–2012)

• Opens: brake fluid, clutch fluid, gearbox oil
• Renewed: slave cylinder

Don't miss

• Make sure that the intermediate plate is engaged on the sealing flange and fitted on the dowel sleeves (arrows).
• Gearbox mounting and gearbox bracket must be parallel to avoid causing damage to thread of gearbox bracket.
• Install air intake hose. Make sure retaining clip (arrow) snaps onto retaining lug (A).
• Wheels must not be in contact with ground when tightening drive shaft as otherwise wheel bearing could be damaged.

📋 Procedure

1. Make sure that the intermediate plate is engaged on the sealing flange and fitted on the dowel sleeves (arrows).
2. Check release bearing for wear. Renew slave cylinder and release bearing if necessary .
3. Check that clutch plate is centralised .
4. Raise gearbox carefully and move to installation position using gearbox support3282.
5. Align gearbox with engine and install.

6. Secure gearbox and starter to engine and tighten bolts to specified torque .
7. Install drive shaft (left-side) (1).
8. Remove engine support3300 A and support T10036.
9. Insert gate relay lever (1) and secure with securing clip (arrow).
10. Insert gate relay lever together with cable end-piece.
11. Attach gearbox bracket to gearbox with new hexagon bolts (arrows) and tighten to specified torque. Tightening torque
12. 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.]
13. Secure gearbox bracket (1) to gearbox mounting (left) (2) with new hexagon bolts (arrows). Tightening torque
14. ⚠ Do not remove support bracket10 - 222 A 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 . Tightening torques
15. Check mountings of engine/gearbox assembly for correct adjustment, and re-adjust if necessary Engine, mechanics10.
16. Secure catalytic converter to turbocharger (arrows)Engine, mechanics26.
17. If fitted, install small flywheel cover plate (A).
18. Secure left and right drive shaft to gearbox Running gear, front-wheel drive and four-wheel drive40Removing and installing drive shafts.
19. Secure heat shield for drive shaft (right-side) (arrows).
20. Attach bracket (1).
21. Plug connector (2) onto reversing light switch F4.
22. Install radiator cowl (arrows) and attach electrical connector (1).
23. Install air intake hose. Make sure retaining clip (arrow) snaps onto retaining lug (A).
24. Apply a small quantity of brake fluid to new sealing ring (3) and fit on pipe/hose assembly (4).
25. Push pipe/hose assembly (4) into bleeder connection (1) so that retaining clip (2) snaps into place.
26. Pull on pipe/hose assembly to check it is secure.
27. Bleed clutch system .
28. Install cable support bracket on gearbox (arrows).
29. Apply a small quantity of greaseG 000 450 02 to pin (arrow) of gearbox selector lever (1).
30. Push gear selector cable onto pin (arrow) and secure with securing clip (3).
31. Apply a small quantity of greaseG 000 450 02 to pin (arrow) of gate relay lever (2).
32. Push gate selector cable onto pin (arrow) and secure with securing clip (4).
33. Insert gate selector cable in cable end-piece.
34. Adjust selector mechanism .
35. Fit earth wire (1).
36. Install battery tray and battery Electrical system27.
37. Install engine cover panel.
38. Install complete air cleaner housing 24.
39. Check gear oil level in gearbox .
40. Install wheel housing liner (front left) (fasteners 1 ... 3).
41. Install noise insulation (centre) (fasteners 1 and 2).
42. Install noise insulation frame (arrow)50.
43. Install noise insulation (centre) (1)50. [Note: Wheels must not be in contact with ground when tightening drive shaft as otherwise wheel bearing could be damaged.]

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