Installing gearbox, Tiguan all-wheel drive with 2.0 l petrol engine — VW

🧭 Before you start

Check threads, dowel sleeves, intermediate plate and release bearing, mount the gearbox on its support and tilt and raise it into place. Fit the lower bolts and the one next to the bevel box, lift the assembly into position, fit the left mounting with new bolts, then the upper bolts. Refit starter, bevel box carrier in sequence, turbo support, propshaft, subframe, pendulum support, clutch line and selector parts, bleed the clutch and check both oil levels.

Fits: VW Tiguan I (5N, 2007–2016)

• Opens: clutch fluid

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• Hook the intermediate plate into the sealing flange and onto the dowel sleeves before joining.
• Keep the support bracket in place until all mounting bolts are tightened.
• Follow the tightening sequence for the bevel box carrier bolts.
• Renew the stub shaft retaining ring and O-ring.
• Renew the gear selector cable securing clip each time it is removed.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. Install gearbox together with bevel box.
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. Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.
4. Ensure that intermediate plate is hooked into sealing flange and pushed onto dowel sleeves (arrows).
5. Check release bearing for wear. If necessary, renew slave cylinder with release bearing .

6. Insert gearbox support3282 in engine and gearbox jack.
7. Align arms of gearbox support according to holes in adjustment plate.
8. Attach support elements(A) to adjustment plate as illustrated.
9. Screw in support element(C) = pin3282/34.
10. Place gearbox on engine and gearbox jack.
11. Align adjustment plate and gearbox parallel to one another.
12. Position engine and gearbox jack under vehicle. Arrow on adjustment plate points in direction of vehicle travel.
13. Then, screw pin3282/34 into rear hole on gearbox for securing bolt of pendulum support.
14. Now tilt gearbox to left using spindles of gearbox support3282.
15. Then carefully raise gearbox further, observing longitudinal member. [Note: Be careful of all lines when installing gearbox.]
16. Then turn gearbox to installation position via spindles of gearbox support3282.
17. Align gearbox to engine and join.
18. Screw in lower engine/gearbox connecting bolts (arrows) and tighten to specified torque .
19. Screw in engine/gearbox connecting bolt (arrow) next to bevel box (A) and tighten to specified torque .
20. After bottom of gearbox and engine are bolted together, remove gearbox support3282 from gearbox.
21. Remove engine support3300 A and bracket.
22. Align engine and gearbox in installation position. To do this, lift with spindle (arrow) until gearbox contacts left engine/gearbox mounting.
23. Therefore, gearbox must also be raised at differential with engine and gearbox jack and universal supportV.A.G 1359/2. [Note: Use stepladderVAS 5085 to install bolts.To avoid damage to the thread in the gearbox, the gearbox and assembly mounting must be parallel to each other.]
24. Screw in new hexagon bolts (arrows) for left engine/gearbox mounting and tighten to specified torque .
25. ⚠ Do not remove support bracket10-222 A until all bolts securing the assembly mounting have been tightened to specified torque. — Screw in upper engine/gearbox securing bolts (arrows) and tighten to specified torque .
26. Install starter (3)Electrical system27Starter; Removing and installing starter.
27. If necessary, install bleeder connection .
28. Push connector (2) onto reversing light switch F4.
29. If a retainer (1) is installed, secure earth strap with a nut (2).
30. Gearboxes for vehicles with start-stop system: join connector (arrow) to gearbox neutral position sender G701.
31. Bolt bevel box carrier to engine and bevel box, observing tightening sequence of bolts (arrows 1) and (arrows 2).
32. Install support for turbocharger 21Assembly overview - turbocharger.
33. Renew retaining ring (arrow A) and O-ring (arrow B) on stub shaft.
34. Mount drive shaft heat shield, if present, on bevel box (nuts (1)) Running gear, axles, steering40Repairing drive shafts.
35. Bolt propshaft onto bevel box (arrows)39Removing and installing propshaft.
36. Install subframe and suspension links with steering rack Running gear, axles, steering40Subframe, anti-roll bar, suspension links; Assembly overview - subframe, anti-roll bar, suspension links.
37. Attach pendulum support to gearbox; bolt (1) and bolt (2)Running gear, axles, steering40Torque settings for front axle.
38. If front vehicle level sender G78 is present, install it 40Removing and installing front vehicle level sender G78.
39. Attach connector (1) to oil level and oil temperature sender G266.
40. Install charge air hose (arrow 1) and (arrow 2)21Charge air system with turbocharger.
41. Push pipe/hose assembly or pipeline (A) to stop into slave cylinder breather and press down clip (arrow).
42. Test line by tugging on it.
43. Remove hose clamp3094 from supply hose.
44. After removing hose clamp3094, return supply hose to its original shape, if necessary.
45. Bleed clutch system .
46. Check for correct installation position of vacuum hose for brake system, install vacuum hose if necessary 47.
47. Install cable support bracket on gearbox and tighten bolts (arrows) to specified torque .
48. Fit gearbox selector lever (2) and tighten securing nuts to specified torque .
49. Spread a small amount of grease on pin (arrow) of gearbox selector lever (2).
50. Mount gear selector cable; renew securing clip (1) each time it is removed.
51. Install relay lever together with cable end-piece .
52. Adjust selector mechanism .
53. Install battery tray and batteryElectrical system27Removing and installing battery.
54. If complete air filter housing was removed, install it.
55. 24Repairing injection system
56. If removed, install engine cover panel.
57. Connect battery and follow procedure after connecting battery Electrical system27Disconnecting and connecting battery.
58. Check gear oil .
59. Check gear oil in bevel box .
60. Tighten front left wheel housing liner General body repairs, exterior66Wheel housing liner.

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