Transmission (Vehicles With 4 Cylinder Engine), Installing
Transmission (vehicles with 4 cylinder engine), installing, 02M/02Y, 5 & 6 Speed M/T, AWD
Installation is performed in reverse order of removal. Note the following:
Note:
^ Replace self-locking nuts and bolts during assembly work.
^ Always replace bolts that are tightened to torque as well as O-rings and gaskets.
^ Secure all hose connections using hose clamps appropriate for the model type.
^ All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
- Clean input shaft splines and (in case of used clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Always remove excessively applied grease.
^ Clutch plate must be able to be moved back and forth on input shaft.
- Make sure centering sleeves for engine to transmission are installed in cylinder block, install if necessary.
- Check clutch release bearing with hydraulic actuation for wear and replace if necessary.
- Engage intermediate plate at sealing flange and slide onto bushings - arrows -.
- Place transmission above spindles of Transmission Support 3282 to left at an angle.
- Carefully lift vehicle and align with transmission support to installation position.
- Press transmission at front side - arrow - and then at bevel gear transfer case side over engine flywheel.
- Insert transmission.
Vehicles with cast bracket for bevel gear transfer case:
- Insert bracket for bevel gear transfer case before screwing in connecting bolts for engine/transmission.
All:
- Install engine/transmission connecting bolts accessible from bottom. Tightening torques.
Vehicles with cast bracket for bevel gear transfer case:
- Loosely screw in bolts - A to C - of bracket for bevel gear transfer case.
Vehicles with metal bracket for bevel gear transfer case:
- Loosely screw in bolts - A to C - of bracket for bevel gear transfer case.
- Remove Transmission Support 3282 from transmission.
- If installed, install small cover plate - A - for flywheel behind bevel gear transfer case, tighten bolt - arrow -.
- Install engine/transmission connecting bolts accessible from top.
Mounting transmission to engine
Bolt with M8 threaded pin.
Replace bolts.
- To install subframe mount use only new bolts - 1 -.
- Bolt transmission mount to transmission with pendulum support still removed.
- Lift transmission up to transmission support using engine support bridge spindle.
CAUTION! Before screwing bolts, make sure that transmission mount support jigs and transmission support are absolutely parallel so threads will not be damaged. Lift transmission at rear using floor jack, if necessary.
- Replace bolts - 2 -.
- Bolt transmission mount support jig to transmission support.
CAUTION! Only remove Engine Support Bridge 10-222 A when all bolts left and right of subframe mount are tightened to torque.
- Remove engine support bridge.
- Install subframe as follows:
- Bring driveshafts to installation position and hand-tighten bolts.
- Move subframe to installation position.
- Install bolts for subframe but do not tighten.
- Position steering gear on subframe and install bolts for steering gear but do not tighten.
^ Threaded sleeve - 1 - must sit in bore of subframe.
^ The rubber buffer on opposite side must fit on subframe molding.
- Install steering gear.
- Bolt on subframe using new bolts.
- Bolt on driveshafts to transmission drive flanges.
TT Roadster:
- Install diagonal members.
All:
- Install right driveshaft heat shield - arrows -.
- Bolt on pendulum support to transmission using new bolts - arrows B -.
- Press engine/transmission assembly to bulkhead; while doing so, carefully guide pin of bevel gear transfer case into driveshaft flange.
- Press driveshaft horizontally onto guide pin.
CAUTION! Make sure not to damage seal - arrow - in flange of drive axle when removing and installing. If seals are damaged, driveshaft must be replaced.
- Bolt on pendulum support to subframe using new bolts - arrows A -.
- Bolt driveshaft to flexible disc at bevel gear transfer case - arrows -.
- Install exhaust system tension-free.
- Press pressure line - 1 - into hose coupling and secure using retainer.
CAUTION! Clutch pedal must not be operated before bleeding clutch system.
- Remove Hose clamps up to 25 mm dia. 3094.
- Connect electrical harness connector at Back-Up Light Switch F4 - 2 -.
- Install starter and install lower bolt. Tightening torques.
- Install power steering line to transmission - arrows -.
- Install pressure line - 2 - at power steering pump using new seals.
- Remove Hose clamps up to 25 mm dia. 3094.
- Connect electrical harness connector - 1 - to pressure switch for power steering.
Vehicles with 2 charge air coolers:
- Install power steering pulley and ribbed belt.
Vehicles with 2 charge air coolers and TT Roadster:
- Install tubular cross member.
All:
- Check gear oil level in manual transmission with bevel gear transfer case Gear oil in manual transmission with bevel gear transfer case.
- Install sound insulation.
Vehicles with 1 charge air cooler:
- Install air guide pipe to charge air cooler at lower right of long-member.
All:
- Install upper mounting bolt on starter. Tightening torque.
- Connect electrical harness connector - 3 -.
- Bolt on bracket - 2 -, insert wiring and engage harness connector in bracket.
- Bolt on Ground (GND) strap - 1 -.
- Install shift rod lever - B - with shift cable at shift rod, to do so tighten nut - arrow 3 -.
- Install linkage lever - A - with selector cable, insert securing ring - arrow 2 - while doing so.
- Tighten nut - arrow 1 -.
- Tighten cable mounting bracket on transmission - arrows -.
- Connect electrical harness connector to Speedometer Vehicle Speed Sensor (VSS) G22 - arrow -.
- Check for tension-free installation of subframe mount for engine and transmission.
- Bleed clutch system.
- Adjust shift mechanism.
- Install battery and battery holder, observe safety precautions after connecting battery.
- Install air filter housing.
- Install engine cover.
Tightening torques
