Note: Replace bolts that have been overtightened. Replace self-locking nuts and bolts and seals. rings, gaskets and seals. cuffs Hose fittings, as well as air ducts and hoses of the air charging 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 ducts in the fittings, before installation, the screw spirals in the already used hose clamps should be sprayed with a corrosion solvent. When installing, install all binders in their places.
Depending on the design and engine, there are 2 different versions of the ATF filter. Remove the ATF main filter -5- and the ATF replacement filter -10-. The ATF replacement filter -10- must be replaced every time the ATF is replaced or when repairs are carried out on the gearbox. The ATF main filter -5- must be replaced when replacing the gearbox or if the ATF is heavily contaminated. Risk of damage to parts. When replacing a manual transmission with a master's degree. With an ATF filter -5- on a gearbox with a replaceable ATF filter -10- the ATF supply and return lines must be replaced. ATF lines are NOT the same. Failure to replace the ATF lines will result in leaks and damage to the ATF lines. The ATF replacement filter -10- will need to be replaced every time the ATF is changed in the future. Make appropriate entries in the vehicle characteristics and repair history. Due to certain circumstances, the replacement of a replacement ATF automatic filter is not displayed in the maintenance tables. If a gearbox with a replaceable ATF filter is installed, then it is necessary to ensure that a hose breather is installed.
Checking the correct installation of the breather hose - vehicles with a gearbox with a replaceable ATF filter
The corner of the breather hose -2- must be pressed onto the connecting fitting -1-. Press the loose corner until it secures. Check that the clamping socket -4- is correctly seated: the distance from the rear clamping socket to the housing flange must be 130 mm. The ATF breather -3- must remain free.
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After replacing the gearbox or after repairing the gearbox, clean the ATF lines and cooler. Before installing the gearbox, be sure to clean the threaded holes connecting the engine and gearbox in the cylinder block using a tap. Danger of depressurization of the ATF pan. Do not touch the ATF pan with the gearbox support -T40173-. Place the powertrain lift with the prepared gearbox mount -T40173- under the gearbox. At the front, the gearbox mount must be installed as follows: on the left side, the mounting block -2- fits into the hole for the flywheel on the gearbox housing; On the right side of the gearbox, the elastic mounting gasket for the gearbox -1- touches the central differential housing.
Secure the gearbox using the tensioning belt -1-. Before connecting the engine and gearbox, carry out the following preparatory steps. Install the auxiliary mounting device -T40169- from below into the gearbox housing and into the clutch module, as shown in the figure. The mounting device must fit into the semicircular groove -1 - and additionally into the control hole -2-. There is only one inspection hole around the perimeter; turn the clutch module accordingly. Insert the bolts of the mounting device into the hole on the gearbox housing.
Place the transport protection -T40170- from below under the gearbox housing and attach it to the flange shaft -1-. Check the aluminum bolts connecting the engine to the gearbox for reuse and mark if necessary.
Vehicles with 2.0 l TFSI engine: Check the presence of engine and gearbox centering sleeves -A- in the cylinder block, insert the sleeves if necessary. Place the engine on the gearbox and tighten the bolts -6- and -7- of the engine/gearbox connection.
Vehicles with 2.0 l TDI engine: Check the presence of engine and gearbox centering sleeves -A- in the cylinder block, insert the sleeves if necessary. Place the engine on the gearbox and tighten the bolts -6- and -7- of the engine/gearbox connection.
Vehicles with 3.2 l FSI engine and 3.0 l TDI engine: Check the presence of engine and gearbox centering sleeves -A- in the cylinder block, insert the sleeves if necessary.
Place the engine on the gearbox and tighten the bolts -6- and -7- of the engine/gearbox connection.
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Screw on the tunnel type cross beam. The picture does not show the tilter. Lower and set aside the lift with gearbox mount J40173-. Tighten the engine-to-gearbox mounting bolts accessible from below. Remove transport protection -T40170- and mounting device -T40169-. The next stage of work is necessary to ensure uniform contact with the driven disk without distortion. Press clutch module -2- using mounting lever -1- onto driven plate -3-arrow-.
Vehicles with 2.0 l TFSI engine and 2.0 l TDI engine: Tighten the clutch module bolts on the driven plate as follows: Screw in the first bolt -arrow- all the way (2 Nm).
Vehicles with 2.0 l TFSI engine: Rotate the crankshaft at the central bolt of the damper using counterhold -T10355- 240°in the direction of engine rotation. - Do not take the arrow into account. With the crankshaft in this position, tighten the accessible bolt to the specified torque. Further rotate the crankshaft by 120°and tighten the remaining 2 bolts to the specified tightening torque.
Vehicles with 2.0l TDI engine: Rotate the crankshaft at the central bolt of the damper 240°in the direction of engine rotation. -Arrows- ignore. With the crankshaft in this position, tighten the accessible bolt to the specified torque. Further rotate the crankshaft by 120°and tighten the remaining 2 bolts to the specified tightening torque.
Vehicles with 3.2 l TFSI engine and 3.0 l TDI engine: Tighten the bolts of the clutch module on the driven plate as follows: Screw in the first bolt -arrow- all the way (2 Nm).
Insert the guide pin of the adapter -T40058- as follows: the large diameter -arrow 1 - faces the engine, the small diameter -arrow 2- points towards the adapter.
Using adapter -T40058-, rotate the crankshaft of the vibration damper 180°in the direction of engine rotation -arrow-. With the crankshaft in this position, tighten the accessible bolt to the specified torque. Further rotate the crankshaft by 60°and tighten the remaining 5 bolts to the specified tightening torque.
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Installation is in reverse order, observing the following. Screw the universal joint to the steering gear. Install the selector cable. Install ATF lines. Screw the left and right drive shafts to the gearbox flange shafts. Install the heat insulating shield of the drive shaft. Use the vehicle data plate or the rear final drive marking to determine the type of rear final drive installed. Then select the appropriate repair manual for the rear final drive. Install the driveshaft.
Vehicles with 2.0 l TFSI engine and 2.0 l TDI engine: Bolt -2- secures the starter to the gearbox and is additionally equipped with a spacer sleeve -arrow-. A spacer must be installed between the starter and gearbox.
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Install the starter. Tighten the remaining bolts -3...5- of the engine/gearbox connection. Install the exhaust system and secure it without mechanical stress. Install cross braces on the subframe. Install the hinge shaft covers and sound insulation. Fill with power steering hydraulic fluid. Perform the necessary actions after connecting the battery. Check and adjust the selector cable.
Tightening torques (Nm)
Note: The tightening torques only apply to lightly lubricated, oiled, phosphated or blued nuts and bolts. It is allowed to use additional lubricants such as engine or transmission oil, other than graphite-containing lubricants. Do not use degreased parts. Torque tolerance±15%.
Bolts and nuts | |
M6 | 9 |
M7 | 15 |
M8 | 20 |
M10 | 40 |
M12 | 65 |
Drive Shaft Heat Shield Torque
Tighten the bolts -arrows- of the heat insulation shield of the drive shaft to a torque of 23 Nm.
Double clutch gearbox for 2.0 l TFSI engine
Pos. | Bolt | Nm |
1 (1) | M 10x50 (2) | 65 |
2 (3), 7 | М12Х100 (4) | 30 + 90° |
3 (5), 6 | M 12x75 (4) | 30 + 90° |
4, 5 (5) | М12Х120 (4) | 30 + 90° |
8,9 | M10X75 (4) | 15 + 90° |
10 | M12X50 (4) | 30 + 90° |
A | Centering sleeves |
Double clutch gearbox for 3.2l FSI engine
Pos. | Bolt | Nm |
1 (1) | M 10x50 (2) | 65 |
2 (3), 3...6 | M12x100 (4) | 30 + 90° |
7 | M12x125 (4) | 30 + 90° |
8, 9, 10 | M10x60 (4) | 15 + 90° |
A | Centering sleeves |
Double clutch gearbox for 2.0 l TDI engine
Pos. | Bolt | Nm |
1 (1) | M10x60 (2) | 65 |
2 (3) | М12Х100 (4) | 30 + 90° |
3 (5), 6 | M 12x75 (4) | 30 + 90° |
4,5 | M12x120 (4) | 30 + 90° |
7,8 | M10x60 (4) | 15 + 90° |
9 | M10x60 (4) | 30 + 90° |
A | Centering sleeves |
- (1) Additionally, attach the starter.
- (2) Bolt strength is 10.9, steel bolt can be used an unlimited number of times.
- (3) Additionally secures the starter; equipped with additional spacer between the starter and gearbox.
- (4) Bolts can be used twice.
- (5) Additionally secures the wiring bracket.
Double clutch gearbox for 3.0 l TDI engine
Pos. | Bolt | Nm |
KP | M 10x50 (2) | 65 |
2 (3), 3...6 | M 12x100 (4) | 30 + 90° |
7 | М12Х125 (4) | 30 + 90° |
8 | M10x60 (4) | 15 + 90° |
9,10 | M10x95 (4) | 15 + 90° |
A | Centering sleeves |
- (3) Additionally, attach the starter.
Aluminum bolts can be used twice. Therefore, after the first use, mark such bolts with two notches using a cutter "X" -arrow-. To avoid damaging the bolts when notching, do not secure them in a vice. Insert the bolt, as shown in the figure, into the 14mm socket using a 1/2p drive, which can then be secured in a vice. Tagged "X" Do not reuse bolts.
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