Installation of control unit
Replace bolts that are tightened with additional tightening. Aluminum engine-to-manual transmission mounting bolts may be reused. Replace the self-locking nuts and bolts, as well as the seals. rings, gaskets and seals. cuffs. Secure all hose connections with hose clamps of the appropriate standard. When installing, install all cable ties in their original places. Install the gearbox on the gearbox mount "T40173" and secure with tension belt "1", as shown in the figure.
Check the primary shaft at the installation location in the driven disk "arrow" for signs of running-in. If necessary, replace the driven disk needle bearing.
Check the presence of centering bushings "A" for the engine and gearbox in the cylinder block; insert the bushings if necessary. If necessary, check for reuse and mark the aluminum bolts "2...11" connecting the engine and gearbox.
Install the clutch module if necessary. Before connecting the engine and gearbox, carry out the following preparatory actions. Install the auxiliary mounting device "T40169" from below into the gearbox housing and into the clutch module, as shown in the figure. Mounting tool "T40169" should fit into semicircular groove "1" and additionally into inspection hole "2." There is only one inspection hole around the perimeter; rotate the clutch module accordingly.
Insert mounting bolts. device into the hole in the gearbox housing. Install the "T40170" transport protection underneath the gearbox housing and attach it to the shaft with flange "1.".
Raise the gearbox so that clutch slave cylinder "1" can be installed. Tighten bolt "2".
The next step is only necessary if the driven disc with locking pin "2" is installed. Additionally, align the position of the driven disc in relation to the clutch module so that locking pins "2" (if available) on the driven disk could enter the large holes "1" on the clutch module. The problem is in the operation of the clutch due to incorrect installation. If the retaining pins of the driven disk "2" do not enter the holes of the clutch module "1", this can lead to serious problems in the operation of the clutch.
Place the engine against the gearbox and tighten bolts "6...11" connecting the engine/gearbox.
Install the starter and hand tighten bolt "3" on the engine side. Insert spacer sleeve "2" between the starter and gearbox, tighten bolt "1". Tighten starter bolts "1" and "3".
Raise the gearbox with an engine and gearbox lift until the gap "a" between the tunnel cross member and the body is reached. Dimension "a" = minimum 80 mm.
Tighten shift fork rod "1". Tighten connecting rod "3". Connect plug connection "2" of gear detection sensor "F208".
Install the gearshift lever as follows: gearshift lever "2" can be installed on shift shaft "1" in only one position (the notch in the gear ring "arrow"). Screw in and tighten the gearshift lever.
Vehicles with start-stop system: Connect the plug of the neutral position sensor of the gearbox "6701" "1".
All
Loosen the lead screws "10-222 A/11". Continue raising the gearbox and tighten the tunnel crossmember "arrow" bolts.
Bolt the left and right drive shafts to the shafts with the gearbox flange.
Install the drive shaft heat shield.
Tightening sequence - clutch module to driven disc
Remove mounting tool "T40169" and transport protection "T40170". Engage the transmission by removing shift shaft "1" and shifting gearshift lever "2" forward in the direction of the arrow.
The next stage of work is absolutely necessary to ensure uniform contact with the driven disk without distortion. Rotate both front wheels in the same direction until the clutch module completes 1 full revolution. The inspection hole "arrow" should be visible again in the recess of the gearbox housing.
Tighten the clutch module bolts to the driven disc as follows. Use new bolts. Tightening torque. Tighten the bolts with a 16 mm ring spanner "VAG1332/14". Tighten the first bolt "arrow" by hand (2 Nm). Rotate the clutch module 120° in the direction of engine rotation using the front wheels and tighten the second bolt also by hand (2 Nm). Rotate the clutch module again 120° in the direction of engine rotation. Then screw in and tighten the 3rd bolt. Now tighten the 2 remaining bolts to the specified tightening torque.
Installation in reverse order. Bolt the universal joint to the steering gear. Assemble the system. exhaust and align without tension.
Install the subframe spacer crosspiece. Check the oil level in the manual transmission. Install noise insulation. Take into account the measures required after connecting the battery.
Tightening torques (Nm)
| Bolts and nuts | M6 | 9 |
| M7 | 15 | |
| M8 | 20 | |
| M10 | 40 | |
| M12 | 65 |
PTO shaft heat shield - tightening torque
Tighten the drive shaft heat shield arrow bolts to 23 Nm.
Mounting the engine to the manual transmission
| Pos. | Bolt | Nm |
| 1 (1) | M10x50 (2) | 65 |
| 2 (3), 7 | M12x100 (4), (5) | 30 + 90° |
| 3 (6), 6 | M12x75 (4), (5) | 30 + 90° |
| 4, 5 (6) | M12x120 (4), (5) | 30 + 90° |
| 8...10 | M10x75 (4), (5) | 15 + 90° |
| 11 | M12x50 (4), (5) | 30 + 90° |
| A | Centering bushings | |
(1) Additionally secures the starter.
(2) Bolt strength 10.9; this steel bolt can be used repeatedly.
(3) Additionally secures the starter; equipped with an additional spacer sleeve between the starter and the gearbox.
(4) Audi A4 up to ID. numbers 8K-9-066499: replace aluminum bolts.
(5) Audi A4 with ID. numbers 8K-9-066500: aluminum bolts can be used 2 times.
(6) Additionally secures the wire holder.
Audi A4 with identification. chassis numbers 8K-9-066500: aluminum bolts "2...11" can be used 2 times. Therefore, after the first use, mark such bolts with 2 notches X "arrow". To avoid damaging the bolts when making the notches, do not clamp them in a vice. Insert the bolt as shown in the illustration into the 14 mm socket using a 1/2-inch drive, which can then be clamped in a vice.
Do not reuse bolts marked with "X".
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