Installing gearbox, Golf, Golf Estate, front-wheel drive vehicle with turbo diesel engine — VW

📋 Procedure

1. If the gearbox is to be renewed, the gearbox selector lever and gate relay lever must be transferred to the new gearbox.
2. All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap.
3. The dowel sleeves for centring engine and gearbox must be fitted in cylinder block, install if necessary.
4. Check release bearing for wear. If necessary, renew clutch slave cylinder with release bearing .
5. Align arms of gearbox support according to holes in adjustment plate.

6. Attach support elements(A) to adjustment plate as illustrated.
7. Screw in pin3282/29 instead of support element(C).
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.
11. Secure adapterVW 771/40 in threaded hole of gearbox housing as shown in figure.
12. Secure gearbox to gearbox support3282 using bolt (M10 × 20) (A).
13. Position engine and gearbox jack under vehicle. Arrow on adjustment plate points in direction of vehicle travel. [Note: Be careful of all lines when installing gearbox.]
14. Then carefully raise gearbox.
15. Then rotate gearbox into installation position via spindles of gearbox support3282.
16. Align gearbox on engine dowel sleeves and join.
17. ⚠ Brake fluid may escape out of bleeder on gearbox. — Screw in engine/gearbox connecting bolt (C) and tighten it (⇒ illustration above) .
18. Screw in engine/gearbox connecting bolt (arrow) and tighten it .
19. Screw in remaining lower engine/gearbox securing bolts and tighten them .
20. After bottom of gearbox and engine are bolted together, remove gearbox support3282 from gearbox.
21. Screw in all upper engine/gearbox securing bolts and tighten them .
22. Install gearbox selector lever to gearbox selector shaft and tighten hexagon nut .
23. Install gate relay lever together with cable end-piece .
24. ⚠ 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. — Install gearbox bracket (1) with new bolts (arrows).
25. Align engine/gearbox assembly in installation position; to do so, tighten spindles of engine support bracket10 - 222 A until gearbox support (1) makes contact with gearbox mounting (2).
26. Screw in new bolts and tighten them (arrows). [Note: Install engine and gearbox mounting free of tension 10Removing and installing engine; Installing engine.]
27. If present, install earth wire (arrow).
28. Do not remove engine support bracket10 - 222 A until all bolts securing the assembly mounting have been tightened to specified torque.
29. Connect pipe/hose assembly to bleeder connection .
30. After removing the hose clamp3094, the supply hose must be returned to its original shape.
31. Bleed clutch mechanism .
32. Check for correct installation position of vacuum hose for brake system. Fit vacuum hose if necessary Brake system47Brake servo/main brake cylinder.
33. Install cable support bracket to gearbox and tighten bolts and nuts (arrows).
34. Insert gate selector cable in cable end-piece.
35. Spread a small amount of grease on pin (arrow) of gearbox selector lever (2).
36. Renew securing clip (1) after each removal.
37. Install starter Electrical system27Starter.
38. If necessary, install bleeder connection .
39. Connect connectors on front left of gearbox:
40. Install drive shafts Running gear, axles, steering40Drive shaft; Removing and installing drive shaft.
41. Install drive shaft heat shield, if present Running gear, axles, steering40Drive shaft.
42. Install subframe together with pendulum support Running gear, axles, steering40Subframe; Assembly overview - subframe. [Note: On some gearboxes, there are threaded inserts, e.g. "“Heli coil”", in the bolting holes for the pendulum support .]
43. Install pendulum support with new bolts 10Assembly mountings; Assembly overview - assembly mountings.
44. Install engine and gearbox mounting free of tension 10Removing and installing engine.
45. Assemble exhaust system 26Emission control; Assembly overview – emission control.
46. Fit connector (1) to oil level and oil temperature sender G266.
47. Check oil level in gearbox Checking gear oil level.
48. If unclipped, carefully clip in pipe for air conditioning. Do not disconnect pipe/hose system Heating, air conditioning87Refrigerant circuit; System overview - refrigerant circuit.
49. Install fuel filter. Do not disconnect any lines 20Fuel filter; Assembly overview - fuel filter.
50. Adjust selector mechanism
51. Install battery tray, battery and battery cover Electrical system27Battery; Removing and installing battery.
52. Install complete air filter housing 23Air filter; Removing and installing air filter housing.
53. Install engine cover panel 10Engine cover panel; Removing and installing engine cover panel.
54. Install plenum chamber cover General body repairs, exterior50Bulkhead; Removing and installing plenum chamber cover.
55. Install wiper arms Electrical system92Windscreen wiper system; Removing and installing wiper arms.
56. Install lower part of front left wheel housing liner General body repairs, exterior66Wheel housing liner; Assembly overview - front wheel housing liner.
57. Install noise insulation General body repairs, exterior66Noise insulation; Assembly overview - noise insulation.
58. If corrosion protection was damaged, repair it using materials specified by manufacturer Paintwork manual.

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