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

🧭 Before you start

Fits: Audi A3 (8P, 2003–2012)

• Opens: brake fluid, clutch fluid, gearbox oil

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• 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. Check that dowel sleeves (arrows) for centralising engine/gearbox are in the cylinder block; install if necessary.
2. Make sure that the intermediate plate is engaged on the sealing flange and fitted on the dowel sleeves (arrows).
3. Check that clutch plate is centralised .
4. Check release bearing for wear. If necessary, renew slave cylinder with release bearing .
5. Raise gearbox carefully and move to installation position using gearbox support3282.

6. Join gearbox to engine, taking care not to trap wiring or other connections.
7. Secure gearbox and starter to engine. Tightening torque
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 bracket10-222A 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 . Tightening torques
15. Check mountings of engine/gearbox assembly for correct adjustment, and re-adjust if necessary Engine, mechanics10.
16. Install radiator cowl (arrows) and attach electrical connector (1).
17. Install air intake hose. Make sure retaining clip (arrow) snaps onto retaining lug (A).
18. Attach bracket (1).
19. Plug connector -2- onto reversing light switch F4.
20. Assemble exhaust system and align so it is free of stress 26.
21. Install small flywheel cover plate (A).
22. Bolt drive shaft (right-side) to gearbox flange shaft (A)Running gear, front-wheel drive and four-wheel drive40.
23. Then fit protective cap for inner right constant velocity joint on engine (arrows).
24. Bolt drive shaft (left-side) to gearbox flange shaft Running gear, front-wheel drive and four-wheel drive40.
25. Apply a small quantity of brake fluid to new sealing ring (3) and fit on pipe/hose assembly (4).
26. Push pipe/hose assembly (4) into bleeder connection (1) so that retaining clip (2) snaps into place.
27. Pull on pipe/hose assembly to check it is secure.
28. Remove hose clamp3094.
29. Bleed clutch system .
30. Apply a small quantity of greaseG 000 450 02 to pin (arrow) of gearbox selector lever (1).
31. Push gear selector cable onto pin (arrow) and secure with securing clip (3).
32. Apply a small quantity of greaseG 000 450 02 to pin (arrow) of gate relay lever (2).
33. Push gate selector cable onto pin (arrow) and secure with securing clip (4).
34. Insert gate selector cable in cable end-piece.
35. Adjust selector mechanism .
36. Fit earth wire (1).
37. Install battery tray and battery Electrical system27.
38. Install air cleaner housing 23.
39. Install engine cover panel.
40. Check gear oil level in gearbox .
41. Install wheel housing liner (left-side).
42. Install noise insulation (bottom) (fasteners 1 ... 3).
43. Install noise insulation frame (arrow)50.
44. 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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