Make sure that the guide bushings "A" for aligning the engine and gearbox in the cylinder block are present; if necessary, insert the missing bushings. If necessary, check for reuse and discard 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. Insert mont. device "T40169" from below into the gearbox housing and install the clutch module as shown in the figure. Mounting tool "T40169" should fit into semicircular groove "1" and additionally into inspection hole "2." To locate the inspection hole, it is necessary to rotate the clutch module. 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".
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. 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.
Install the gearbox onto the engine and tighten bolts "3...11". 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 using a powertrain lift until the gap "a" between the tunnel crossmember and the body is reached. Size "a" = not less than 80 mm.
Tighten shift fork rod "1". Tighten connecting rod "3". Attach connector "2" of gear detection sensor "F208".
Install gearshift lever "2" as follows. Gearshift lever "2" can be installed on gearshift 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 connector of the neutral position sensor of the gearbox "G701" "1".
All
Loosen the lead screws "10-222 A/11". Continue raising the gearbox and tighten the tunnel crossmember "arrow" bolts. Remove the tilter and mounting. bracket "T40173".
Bolt the left and right drive shafts to the shafts with the gearbox flange.
Install the drive shaft heat shield.
Install the driveshaft or bolt it to the gearbox. Secure the driveshaft. To do this, install the support "T10172" with "T10172/5" on the bolts securing the propeller shaft to the gearbox or rear final drive.
Bolt tightening sequence - clutch module to driven disc
Remove mounting tool "T40169" and transport protection "T40170". Engage 6th gear 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 fronts. wheels in one direction so that the clutch module makes 1 full revolution. The inspection hole "arrow" should be visible again in the recess of the gearbox housing.
Tighten the clutch module bolts on the driven disc as follows. Use new bolts. Tighten the bolts with a 16 mm ring spanner "VAG 1332/14". Tighten the first bolt "arrow" by hand (2 Nm). Turn the clutch module using the front. wheels 120° in the direction of engine rotation and tighten bolt 2 by hand (2 Nm). Turn 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.
If present, install the heat shield for the driveshaft "A" and tighten the "arrow" bolts to 25 Nm. Align the system. exhaust gas release without mechanical stress.
Install the subframe crosspiece. Check the manual transmission oil level. Install noise-insulating shields. Pay attention to the battery installation work.
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.
Fastening the engine to the manual transmission
| Pos. | Bolt | Nm |
| 1 (1) | M10 x 50 (2) | 65 |
| 2 (3), 7 | M12 x 100 (4), (5) | 30 + 90° |
| 3 (6), 6 | M12 x 75 (4), (5) | 30 + 90° |
| 4, 5 (6) | M12 x 120 (4), (5) | 30 + 90° |
| 8...10 | M10 x 75 (4), (5) | 15 + 90° |
| 11 | M12 x 50 (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; 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: Use aluminum bolts twice.
(6) Additionally secures the electrical cable bracket.
Audi A4 with identification. part numbers 8K-9-066500: Aluminum bolts "2...11" may be used no more than twice. Therefore, after the first use, mark these bolts with two notches "X" and "arrow" using a cutter. To avoid damaging the bolts during notching, 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".
A link to the original source is available on the website AUDIMANUAL.ru