Installing gearbox, Golf Sportsvan, Touran, with turbo diesel engine — VW

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 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. Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and 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. Bolt assembly tool T10519 to engine and subframe as shown in illustration. Tighten bolt to 20 Nm. — 20 Nm (15 lb-ft)
7. Position engine support3300 A. Tighten bolt to 20 Nm. — 20 Nm (15 lb-ft)
8. Push engine forwards, making sure not to strike against radiator.
9. When doing this, observe the following points:
10. Align arms of gearbox support according to holes in adjustment plate.
11. Screw in support elements(A) and (C) (pin3282/29) on adjustment plate as shown.
12. Place gearbox on engine and gearbox jack.
13. Align adjustment plate and gearbox parallel to one another.
14. Then screw pin3282/29 into rear hole on gearbox for securing bolt of pendulum support. [Note: Be careful of all lines when installing gearbox.]
15. Position engine and gearbox jack under vehicle. (Arrow B) on adjustment plate points in direction of vehicle travel.
16. Lower gearbox in vicinity of differential in direction of (arrow) onto stop (different gearbox shown in illustration).
17. Have a second mechanic push engine towards front-end.
18. Carefully lift gearbox, guiding right-hand flange shaft (A) past dowel sleeve in cylinder block (arrow) as shown.
19. Observe area of coolant hose (1) and starter mounting (2) when guiding gearbox past subframe (3) (⇒ previous illustration).
20. Guide left flange shaft (B) past subframe bracket (arrow) as shown.
21. Then swivel gearbox with flange shaft (1) around intermediate plate (arrow); if necessary restore original shape of intermediate plate.
22. Using spindles of gearbox support3282, tilt gearbox upwards in vicinity of differential.
23. Lift gearbox to engine.
24. Align gearbox to engine and join.
25. Screw in bolt for engine/gearbox in the area of right flange shaft and tighten them (arrow).
26. Screw in lower engine/gearbox securing bolts and tighten it .
27. After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.
28. Remove engine support3300 A and assembly tool T10519.
29. Screw in upper engine/gearbox securing bolts and tighten them .
30. Install bracket (A) on gearbox using new hexagon bolts (arrows) and tighten bolts .
31. Have a second mechanic push gearbox towards plenum chamber bulkhead then locate gearbox mounting with a screwdriver (shown here with a different gearbox).
32. Align engine and gearbox in installation position. To do this, lift until gearbox is in contact with assembly mounting.
33. Screw in new bolts (arrows) by hand.
34. Tighten new bolts (arrows). [Note: Install engine and gearbox mounting free of tension 10Removing and installing engine; Installing engine.]
35. Do not remove engine support bracket10 - 222 A until all bolts securing the assembly mounting have been tightened to specified torque.
36. If present, install earth wire (arrow).
37. Install pendulum support with new bolts 10Assembly mountings; Assembly overview - assembly mountings.
38. Assemble exhaust system 26Emission control; Assembly overview – emission control.
39. Install drive shafts Running gear, axles, steering40Drive shaft; Removing and installing drive shaft.
40. If present, install drive shaft heat shield (arrows)Running gear, axles, steering40Drive shaft; Removing and installing drive shaft.
41. If present, bolt front vehicle level sender G78 to transverse link Running gear, axles, steering43Vehicle level sender; Assembly overview - front vehicle level sender.
42. Install coupling rod (3) to anti-roll bar (2) on both sides Running gear, axles, steering40Subframe; Assembly overview - subframe.
43. Connect connector (1) to oil level and oil temperature sender G266.
44. Install starter and retainer for electrical wiring (arrow)Electrical system27Starter.
45. Gearboxes for vehicles with start-stop system: join connector (arrow) to gearbox neutral position sender G701.
46. Install clutch slave cylinder and tighten bolts (arrows B).
47. Then install gearbox support (arrows A) and tighten .
48. Push connector (1) onto reversing light switch F4.
49. Attach connector (arrow 2) and wire (arrow 3) to starter Electrical system27Starter.
50. If fitted, connect earth strap at top.
51. Check for correct installation position of vacuum hose for brake system. Fit vacuum hose if necessary Brake system47Brake servo/main brake cylinder.
52. If fitted, attach bracket (B) to gearbox.
53. If necessary, press pipe/hose line (A) into bracket (B) on gearbox.
54. Install cable support bracket on gearbox and tighten bolts (arrows).
55. Install gearbox selector lever (A).
56. Tighten hexagon nut (arrow 3).
57. Spread a small amount of grease on pin of gearbox selector lever (A).
58. Attach gear selector cable to gearbox selector lever.
59. Renew securing clip (arrow 2) each time after removing.
60. Install gate relay lever together with cable end-piece .

Other VW procedures

• Removing engine · 41 torque figures
• Removing and installing camshaft · 47 torque figures
• Adjusting valve timing · 83 torque figures
• Removing and installing camshafts · 39 torque figures
• Removing and installing coolant pump · 53 torque figures
• Removing and installing starter battery in vehicle interior
• Removing and installing power take-off housing cover
• Repair work on auxiliary air heaters Airtronic D2 and D4S
• Removing and installing curtain airbag in front seat area
• Removing and installing axle assembly