Gearbox removal & installation: VW Notes on installing (2E, AAM, ABS, ACK, …)

🧭 Before you start

Fits: VW Sharan I / SEAT Alhambra (7M)

• Opens: brake fluid

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• Before starting assembly mounting bolts, bracket (B) must be installed and tightened; torque settings for bracket .
• Specified torques for engine and gearbox mountings .

🔧 Engine codes this applies to

🔩 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. ⚠ When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original positions.Ensure that there is sufficient clearance to all moving or hot components. — Check whether dowel sleeves for centring engine/gearbox have been fitted in cylinder block, insert if necessary.
2. Hook intermediate plate onto sealing flange and slide onto dowel sleeves (arrows).
3. Clean input shaft splines and lightly grease with greaseG 000 100.
4. Check clutch and clutch operating mechanism and install 30.
5. Clean input shaft splines and lightly grease with G 000 100.

6. Check clutch and clutch operating mechanism and install 30.
7. Screw in all bolts on assembly mountings by hand approx. 5…6 turns. [Note: Before starting assembly mounting bolts, bracket (B) must be installed and tightened; torque settings for bracket .]
8. Align assembly mountings stress-free by rocking. [Note: Specified torques for engine and gearbox mountings .]
9. Fit pipe/hose line to slave cylinder and secure with clamp 30.
10. Install actuator cables on gearbox; adjust if necessary 34.
11. Fit pipe/hose line to slave cylinder and secure with clamp 30.
12. Install actuator cables on gearbox; adjust if necessary 34.
13. Install gate lever cable on gearbox, adjust if necessary 37.
14. Install gate lever cable on gearbox, adjust if necessary 37.
15. Install front exhaust pipe ; front exhaust pipe and catalytic converter with attachments.
16. Install drive shafts 40.
17. Install pendulum support 40.
18. Install power-assisted steering vane pump 48.
19. Bolt hydraulic line for power-assisted steering onto right engine bracket; torque setting 20 Nm. — 20 Nm (15 lb-ft)
20. Install air conditioner compressor 87.
21. Install poly V-belt .
22. Install air pipes between turbocharger/charge air cooler, turbocharger/air filter and charge air cooler/throttle valve control module , Removing and installing parts of the charge air cooling system: engine code AJH
23. Install intake hose , Removing and installing parts of the charge air cooling system: engine code AJH.
24. Install pressure hose between secondary air pump motor V101 and combination valve , Removing and installing parts of the secondary air system.
25. Adjust throttle cable , Repairing accelerator mechanism.
26. Install air pipes between turbocharger/charge air cooler, turbocharger/air filter and charge air cooler/throttle valve control module , Removing and installing parts of charge air cooling system: engine code AWC
27. Install intake hose , Removing and installing parts of charge air cooling system: engine code AWC.
28. Install pressure hose between secondary air pump motor V101 and combination valve , Removing and installing parts of the secondary air system.
29. Install air filter 24.
30. Install battery and battery tray.
31. Electrical connections and routing .
32. Install noise insulation tray 50.
33. Carry out a road test and interrogate fault memory 01Fault memory; Reading and erasing fault memory.
34. Adapt control unit for engine electronics to throttle valve control module 24.
35. Carry out a road test and interrogate fault memory 01Fault memory; Reading and erasing fault memory.
36. Adapt engine control unit to throttle valve control module and to exhaust gas recirculation valve 24.
37. On vehicles with automatic gearbox, gearbox control unit must also be adapted: Self-diagnosis for 5-speed automatic gearbox 09B01. [Note: Specified torques for engine and gearbox mountings .]

Other VW procedures

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• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures