Table of contents: Tightening torques when installing… ↓ All ↓ All ↓ Tightening torques (Nm) ↓ PTO shaft heat shield - tightening… ↓ Mounting a 2.0L TDI engine to a… ↓ Mounting for 2.0L TFSI engine to… ↓
Note: Replace the bolts that are tightened with additional tightening. Aluminum bolts for fastening the engine to the manual transmission may be used twice. Replace the self-locking nuts and bolts, as well as the sealing rings, gaskets and sealing cuffs. The hose fittings, as well as the air duct tubes and hoses of the air boost system, must be cleaned of oil and grease before installation. Secure all hose connections with hose clamps of the appropriate standard. In order to securely fasten the air boost system hoses in their fittings, before installation, spray the screw spirals in the hose clamps already in use with a corrosion solvent. During installation, reinstall all cable ties in their original places.
Tightening torques when installing the gearbox
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 site in the driven disk "arrow" for signs of running-in. If necessary, replace the driven disk needle bearing.
If necessary, install the clutch module. Before connecting the engine and gearbox, perform the following preparatory actions. Install the auxiliary mounting device "T40169" from below in the gearbox housing and in the clutch module, as shown in the figure. The mounting device "T40169" must enter the semicircular groove "1" and additionally in the inspection hole "2". There is one inspection hole along the perimeter, accordingly turn the clutch module. Insert the mounting device bolts into the hole on the gearbox housing. Install the "T40170" transportation protection from below under the gearbox housing and attach to the shaft with flange "1".
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" of the engine and gearbox in the cylinder block, if necessary, insert the bushings. Raise the gearbox so that the clutch slave cylinder "1" can be installed. Tighten bolt "2".
The next step of the work is necessary only if the driven disk with the locking pin "2" is installed. Additionally, align the position of the driven disk in relation to the clutch module so that the locking pins "2" (if available) on the driven disk could enter the large holes "1" on the clutch module. Problem with the clutch operation due to incorrect installation If the locking pins of the driven disk "2" do not enter the holes in the clutch module, this can lead to serious problems in the operation of the clutch.
If necessary, check for reuse and mark the aluminum bolts "2...11" connecting the engine and gearbox. Place the engine on the gearbox and tighten the bolts "7...11" connecting the engine/gearbox. Bolt "7" is installed only on 4-cylinder TDI engines. Tighten the bolts "arrows" of the tunnel crossmember.
Cars with start-stop system: Connect the plug of the neutral position sensor of the gearbox "G701" "1".
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Install gearshift lever "2" as follows. Gearshift lever "2" can be installed on gearshift shaft "1" only in one position (notch in gear ring "arrow"). Tighten gearshift lever "2".
Tighten the shift fork rod "1".
Tighten the connecting rod "3". Connect the electrical plug connection "2" of the gear detection sensor "F208".
Pin it (if available) on the gearbox bracket "B" with plug connector "C" of the exhaust gas temperature sensor 4 "G648". Fasten the electric wire "A" to the gearbox "arrows".
Install the starter and tighten bolt "3" by hand on the engine side. Insert spacer sleeve "2" between the starter and gearbox, tighten bolt "1". Tighten starter bolts "1" and "3". Tighten the remaining engine-to-gearbox mounting bolts.
Screw the cardan joint to the steering gear.
Tighten the drive shaft bolts on the shafts with the gearbox flange.
Install the drive shaft heat shield.
Install noise insulation "1" in the right wheel arch.
Install the propeller shaft or bolt it to the gearbox. Secure the propeller shaft. To do this, install the "T10172" counter support with "T10172/5" propeller shaft mounting bolts to the gearbox or rear main gear.
Tightening sequence - clutch module to driven disc
Remove the mounting device "T40169" and the transport protection "T40170". Engage 6th gear by removing the shift shaft "1" and shifting the gearbox lever "2" forward in the "direction of the arrow".
The next stage of work is necessary to ensure uniform contact with the driven disk without skewing. Rotate both front wheels in one direction so that the clutch module makes 1 full revolution. The control hole "arrow" should again be visible 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 "V.A.G 1332/14". Screw in the first bolt "arrow" by hand (2 Nm).
Turn the clutch module by 120° in the direction of engine rotation using the front wheels and tighten the second bolt with hand force (2 Nm). Turn the clutch module again by 120° in the direction of engine rotation. Then tighten the third bolt. Now tighten the 2 remaining bolts. Install in the reverse order. If present, install the heat shield for the propeller shaft "A" and tighten the bolts "arrows" to a torque of 25 Nm.
Vehicles with 2.0L TDI engine: Install the particulate filter and exhaust pipe. Install the air filter housing.
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Install power steering lines.
Install the subframe spacer crosspiece. Check the transmission oil level in the manual transmission. Install noise insulation. Install the tensioner. Consider the measures required after connecting the battery. Risk of damage to control units due to overvoltage. Do not use a charger as a starting aid!
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 a 2.0L TDI engine to a manual transmission
| Pos. | Bolt | N·m |
| 1(1) | M 10x50 (2) | 65 |
| 2(3) | M12x100 4) | 30 + 90° |
| 3(5), 6 | M 12x75 (4) | 30 + 90° |
| 4, 5 (5) | M12x120 (4) | 30 + 90° |
| 7...9 | M1 0x75 (4) | 15 + 90° |
| 10 | M12x50(4) | 30 + 90° |
| A | Centering bushings | |
Mounting for 2.0L TFSI engine to manual transmission
| Pos. | Bolt | N·m |
| 1(1) | M10x50 (2) | 65 |
| 2(3) | M12x100 (4) | 30 + 90° |
| 3 5) | M1 2x75(4) | 30 + 90° |
| 4,5(5) | M12x120 (4) | 30 + 90° |
| 6 | M1 2x75 (4) | 30 + 90° |
| 7 | M12x100 (4) | 30 + 90° |
| 8...10 | M1 0x75 (4) | 15 + 90° |
| 11 | M12x50 (4) | 30 + 90° |
| A | Centering bushings | |
- (1) Additionally secures the starter.
- (2) The steel bolt is not replaceable.
- (3) Additionally secures the starter; equipped with an additional spacer sleeve between the starter and gearbox.
- (4) Check the reusability of aluminum bolts and replace if necessary.
- 5) Additionally secures the electrical wire holder.
Aluminum bolts "2...10" can be used twice. Therefore, after the first use, mark such bolts with two notches "X" "arrow".
To avoid damaging the bolts when nicking, do not clamp them in a vice. Insert the bolt as shown in the picture into a 14 mm socket with a 1/2 inch driver, which can then be clamped in a vice. Bolts marked "X" should not be reused. Steel bolt "1" can be reused.
(A link to the original source is available on the website: AUDIMANUAL)