Installing gearbox, CC with 1.8 l petrol engine — VW

🧭 Before you start

Fits: VW CC (358, 2012–2017)

• Renewed: self-locking nuts

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• All threaded holes into which self-locking bolts are to be screwed must be carefully cleaned of residual locking fluid using a thread chaser.
• The dowel sleeves for aligning engine and gearbox must be in cylinder block, install if necessary.
• Ensure that intermediate plate is correctly seated on engine.
• Be careful of all lines when installing gearbox.
• Install engine and gearbox mounting free of tension 10Removing and installing engine; Installing engine.

📋 Procedure

1. All threaded holes into which self-locking bolts are to be screwed must be carefully cleaned of residual locking fluid using a thread chaser.
2. Renew self-locking nuts and bolts after each removal.
3. The dowel sleeves for aligning engine and gearbox must be in cylinder block, install if necessary.
4. Ensure that intermediate plate is correctly seated on engine.
5. Clean input shaft splines and apply thin coat of grease for clutch plate splines.

6. Align arms of gearbox support according to holes in adjustment plate.
7. Screw in support elements(A) and (C) (pin3282/29) on adjustment plate as shown.
8. Place gearbox on engine and gearbox jack.
9. Align adjustment plate and gearbox parallel to one another.
10. Then screw pin3282/29 into rear hole on gearbox for securing bolt of pendulum support. [Note: Be careful of all lines when installing gearbox.]
11. Position engine and gearbox jack under vehicle. (Arrow B) on adjustment plate points in direction of vehicle travel.
12. Tilt gearbox further using spindles of gearbox support3282.
13. Then carefully raise gearbox.
14. Guide gearbox with differential over subframe (A)(in direction of arrow).
15. Note longitudinal member (B).
16. If necessary, have a second mechanic push engine forwards slightly.
17. Guide gearbox with differential over subframe (A), to do this swing gearbox up near 6th gear.
18. Then swivel gearbox with flange shaft (1) around intermediate plate (arrow); if necessary restore original shape of intermediate plate.
19. Align gearbox to engine and join.
20. Screw in lower engine/gearbox securing bolts and tighten them .
21. After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.
22. If small cover plate (A) had been installed behind the right flange shaft (arrows), install it.
23. Screw in upper engine/gearbox securing bolts and tighten them .
24. Install bracket (A) on gearbox using new hexagon bolts (arrows) and tighten bolts .
25. Align engine and gearbox in installation position. To do this, lift until gearbox is fully in contact with left engine/gearbox mounting.
26. Align engine and gearbox in installation position using both spindles of support bracket10 - 222 A.
27. ⚠ Risk of damaging thread in gearbox support if bolts are started at an angle.To avoid damage to the thread in the gearbox support, the gearbox mounting and bracket must be aligned parallel to each other. — Screw in new bolts and tighten them (arrows). [Note: Install engine and gearbox mounting free of tension 10Removing and installing engine; Installing engine.]
28. ⚠ Danger of accident!Do not remove engine support bracket10 - 222 A until all bolts securing the assembly mounting have been tightened to specified torque. — Install pendulum support Running gear, axles, steering40Subframe; Assembly overview - subframe.
29. Install drive shafts Running gear, axles, steering40Drive shaft; Removing and installing drive shafts.
30. If present, install drive shaft heat shield (arrows)Running gear, axles, steering40Drive shaft; Heat shields for drive shafts.
31. Install left coupling rod Running gear, axles, steering40.
32. If present, bolt front left vehicle level sender G78 to transverse link Running gear, axles, steering43Assembly overview - front vehicle level sender.
33. Connect connector (1) to oil level and oil temperature sender G266.
34. Assemble exhaust system and install exhaust system bracket on subframe 26Exhaust pipes/silencers; Assembly overview - silencer.
35. Gearboxes for vehicles with start-stop system: join connector (arrow) to gearbox neutral position sender G701.
36. Bolt charge air pipe to engine 21Assembly overview - charge air system.
37. Install left charge air hose (1)21Assembly overview - charge air system.
38. Install clutch slave cylinder and tighten bolts (arrows B).
39. Then install gearbox support (arrows A) and tighten .
40. Push connector (1) onto reversing light switch F4.
41. Install starter, push on connector (arrow 2) and bolt on wire (arrow 3)Electrical system27.
42. Attach earth strap to top starter bolt.
43. Check for correct installation position of vacuum hose for brake system. Fit vacuum hose if necessary Brake system47Brake servo/main brake cylinder.
44. Attach retainer (B) to gearbox
45. Press pipe/hose assembly (A) into retainer (B) on gearbox.
46. Install cable support bracket on gearbox and tighten bolts (arrows).
47. Install gearbox selector lever (A).
48. Tighten hexagon nut (arrow 3).
49. Spread a small amount of grease on pin of gearbox selector lever (A).
50. Attach gear selector cable to gearbox selector lever.
51. Renew securing clip (arrow 2) each time after removing.
52. Install gate relay lever together with cable end-piece .
53. Connect gate selector cable with cable end-piece.
54. Adjust selector mechanism .
55. Install battery tray, battery and battery cover Electrical system27Battery; Removing and installing battery.
56. Install engine cover panel or air filter cover 24Air filter; Removing and installing air filter housing.
57. Fit foam pieces on upper edge of left and right wings 50Bulkhead; Assembly overview - plenum chamber cover.
58. Install lower part of front left wheel housing liner General body repairs, exterior66Wheel housing liner; Assembly overview - front wheel housing liner.
59. Install noise insulation General body repairs, exterior66Noise insulation; Assembly overview - noise insulation.
60. For vehicles with front left vehicle level sender G78 check headlight adjustment Electrical system94Headlights.

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