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. devices into the hole on the gearbox housing.
Install the "T40170" transport protection from below under the gearbox housing and attach it to the shaft with flange "1".
Check the presence of centering bushings "A" in the cylinder block: engine and gearbox; insert bushings if necessary. If necessary, check for reuse and mark the aluminum bolts "2...10" connecting the engine and gearbox.
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.
Attach the engine to the gearbox and tighten bolts "7...10" connecting the engine to the gearbox. Install the starter and hand-tighten bolt "3": on the engine side. Insert spacer sleeve "2" between the starter and the gearbox, tighten bolt "1". Tighten starter bolts "1" and "3". Install bolt "1" and spacer sleeve "2" on top, on the removed front wall of the water drain box. Use the stepladder "VAS 5085".
Raise the gearbox using the engine and gearbox lift -VAG1383 A- until the gap "a" between the tunnel cross member and the body is reached. Dimension "a" = minimum 80 mm.
Attach bracket "B" with plug connector "C" of exhaust gas temperature sensor 4 "G648" to the gearbox. Attach wire "A" to the gearbox "arrows".
Tighten the shift fork rod "1". Connect the plug connection "2" of the gear detection sensor "F208".
Install the gearshift lever as follows. Gearshift lever "2" can be installed on gearshift shaft "1" in only one position (the notch in the gear ring "arrow"). Tighten gearshift lever "2".
Vehicles with start-stop system: Connect the plug of the gearbox neutral position sensor "G701" "1".
All
Loosen the lead screws "10-222 A/11". Continue raising the gearbox and tighten the bolts of the tunnel crossmember "arrow". Remove the engine and transmission lift with the "T40173" transmission mount from under the transmission. Remove the "10-222 A" crossmember. Tighten the remaining bolts "3...6" connecting the engine/transmission. Bolts "3" and "5" additionally secure the line holders. Screw the connecting rod "3" from above, through the removed front wall of the water drainage box. Pos. "2" and "3" do not take into account.
Raise the front engine mount "1" up until it touches the crossmember in the direction of the arrow. The buffer "2" should be flush with the crossmember without any gap or tension. Then tighten bolts "3" to the specified tightening torque.
Bolt the left and right drive shafts to the shafts with the gearbox flange.
Tightening sequence - clutch module to driven disc
Remove transport lock "T40170" and mounting tool "T40169". Engage the transmission by removing shift shaft "1" and shifting gear 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. 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.
Installation in reverse order. Bolt the universal joint to the steering gear. Install the drive shaft heat shield.
Install the subframe spacer crosspiece. Install the end wall of the water drainage box. If present, install a spacer. Install the particulate filter and exhaust pipe. Install the air casing. filter. Check the oil level in the manual transmission. Install sound insulation. Take into account the measures required after connecting the battery. Fill with coolant.
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 (1) | M12x100 (3), (4) | 30 + 90° |
| 3 (5), 6 | M12x75 (3), (4) | 30 + 90° |
| 4, 5 (5) | M12x120 (3), (4) | 30 + 90° |
| 7...9 | M10x75 (3), (4) | 15 + 90° |
| 10 | M12X50 (3), (4) | 30 + 90° |
| A | Centering bushings | |
(1) Additionally secures the starter.
(2) Bolt strength 10.9; this steel bolt can be used repeatedly.
(3) Audi A4 up to ID. numbers 8K-9-066499: replace aluminum bolts.
(4) Audi A4 with ID. numbers 8K-9-066500: aluminum bolts can be used 2 times.
(5) 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".