Installing gearbox, vehicles up to model year 2010 — VW

Installing gearbox, vehicles up to model year 2010
Install in reverse order of removal, observing the following:
Lubricate needle bearing
arrow
lightly with
high-temperature grease
Electronic Parts Catalogue
.
Slightly grease journal and splines on gearbox.
If there are no dowel sleeves
A
in the cylinder block for centring the engine and gearbox, insert new dowel sleeves.
Check that intermediate plate is hooked into sealing flange and pushed onto dowel sleeves
arrows
.
Note
To install gearbox 02E, set up
gearbox support
3282
with
adjustment plate
3282/42A
.
It is recommended that aligned
gearbox support
3282
should be attached to gearbox when gearbox is hanging from support beam of
gearbox lifting tackle
3336
. Then secure unit with a tensioning strap.
Align arms of
gearbox support
3282
according to holes in
adjustment plate
3282/42 A
.
Fit
support elements
into
adjustment plate
3282/42 A
as illustrated.
Place gearbox with
gearbox support
3282
on
engine and gearbox jack
V.A.G 1383 A
.
Position
engine and gearbox jack
V.A.G 1383 A
under vehicle. Arrow on
adjustment plate
3282/42 A
points in direction of travel.
Tilt gearbox to left using spindles of
gearbox support
3282
. Then raise gearbox.
Align gearbox to engine and place on cylinder block.
It must be possible to guide the engine and gear box together by hand until the flanges make contact all around.
Tighten bolts
5
,
6
,
7
,
8
and
9
to specified torque.
After bottom of gearbox and engine have been bolted together, remove
gearbox support
3282
from gearbox.
Engine and gearbox jack
V.A.G 1383 A
is not required.
Install small cover plate behind right flange shaft.
Insert left drive shaft in wheel bearing housing and place in flange shaft.
Tighten nut of left coupling rod to specified torque.
Place right drive shaft in flange shaft.
Tighten upper engine/gearbox bolts
1
,
3
and
10
to specified torque using
insert tool 18 mm
T10179
.
Bolt
3
is located in the starter motor hole. Use
socket
T10061
for these bolts.
Align engine/gearbox assembly free of tension
Rep. gr.
10
Assembly mountings; Adjusting assembly mountings
.
Screw new bolts
1
of left assembly mounting into gearbox bracket
A
by hand, and tighten them to specified torque.
Screw in new bolts
2
of left assembly mounting by hand, and tighten them to specified torque.
Note
Using a screwdriver, lever gearbox bracket into correct position when tightening bolts
2
.
First renew front bolt of right assembly mounting and then the rear bolt. Tighten bolts
arrows
to specified torque.
Remove
support device
10 - 222 A
.
WARNING
Do not remove
support bracket
10 - 222 A
until the bolts securing the left and right assembly mountings have been tightened to specified torque.
Insert filler pieces of upper edge of left and right wings again.
Install cable support bracket
2
with bolts
1
on gearbox.
Install new securing clip
3
.
Adjust selector lever cable
Chapter
.
Install charge air pipe
Rep. gr.
21
Charge air system; Assembly overview - charge air system
.
Install air filter housing
Rep. gr.
23
Air filter; Removing and installing air filter housing
.
Fit bracket, and tighten nuts
arrows
.
Attach electrical wiring to retainer without damage.
Fit electrical connector for radiator fan in radiator shroud.
Fit drive shafts onto gearbox flange shafts, and tighten them to specified torque.
Tighten left drive shaft to specified torque on wheel bearing housing.
Fit exhaust system bracket to subframe
arrows
, and tighten it to specified torque.
Assemble exhaust system with clamp
arrows
Rep. gr.
26
Exhaust pipes/silencers; Assembly overview – silencer
.
Install pendulum support, and tighten it to specified torque.
Install starter
Electrical system
Rep. gr.
27
Starter; Removing and installing starter
.
Fit connector
A
of
mechatronic unit for dual clutch gearbox
J743
as follows:
Arrows
D
on
mechatronic unit
B
and connector
A
and also lug
C
must all be in line.
Then carefully fit connector
A
as far as it will go and turn locking mechanism in
»clockwise direction«
to lock
direction of arrow
.
Bolt earth wire to gearbox bracket, and tighten it to specified torque.
Install coolant hoses on gear oil cooler and remove hose clamps.
Fit vacuum line on brake servo.
Install battery tray, battery cover and battery
Electrical system
Rep. gr.
27
Battery; Removing and installing battery
.
Connect battery and follow procedure after connecting battery
Electrical system
Rep. gr.
27
Disconnecting and connecting battery
.
Install front left wheel housing liner
General body repairs, exterior
Rep. gr.
66
Wheel housing liners; Assembly overview – front wheel housing liner
.
Check gear oil level if gear oil has leaked out
Chapter
.
Install noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview – noise insulation
.
Replenish coolant, and check coolant level again after road test
Rep. gr.
19
Cooling system/coolant; Draining and filling coolant
.
Specified torques
Chapter
“
Specified torques for gearbox
”
Drive shafts; Assembly overview – drive shafts
Running gear, axles, steering
Rep. gr.
40
Drive shafts; Assembly overview – drive shafts
.
Subframe; Assembly overview – subframe
Running gear, axles, steering
Rep. gr.
40
Subframe
Exhaust pipes/silencers; Assembly overview - silencers
Rep. gr.
26
Exhaust pipes/silencers; Assembly overview - silencers
.