Transmission, Installing In Vehicles With 4-Cylinder

Transmission, installing in vehicles with 4-cylinder engine - 6 Spd. M/T 01X Front Wheel Drive

Installation is perform in reverse sequence; note the following:

- Use a thread tap to remove any remaining locking fluid from all threaded holes which will accommodate self-locking bolts.
- Always replace self-locking bolts and nuts.
- Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease for clutch plate splines G000100 to splines. Do not grease guide sleeve.

It should be possible to push the clutch plate back and forth slightly on the input shaft.





- Check clutch release bearing for wear and replace if necessary.
- If plastic ring - arrows - has come loose, service release bearing as required.

Note:
^ The release bearing must be replaced if the groove worn on the plastic ring is deeper than 0.8 mm.

- Check that dowel sleeves for centralizing engine/transmission are in cylinder block, install if necessary.
- Place intermediate plate on dowel sleeves at engine flange.
- Before installing transmission, tie electrical wires and brackets off to one side so that they are not trapped between engine and the transmission.





- Lightly lubricate surface where operating rod and clutch release lever make contact - arrow B - using copper grease Z381351TE.
- Raise transmission far enough to be able to install slave cylinder with bracket for hose/line assembly.
- Guide slave cylinder - 1 - into opening in transmission housing keeping it as straight as possible (without tilting operating rod - arrow A -) and insert in recess - arrow B - on clutch release lever - 3 -.

Note:
^ If the slave cylinder - 1 - is inserted at an angle, there is a danger that the operating rod - arrow A - will be guided past the clutch release lever - 3 -.

CAUTION!
After installing the slave cylinder carefully press the clutch pedal. If you feel an unusually strong resistance when depressing the clutch pedal, you must not press it down further. The push rod of the slave cylinder is likely to have been guided past the clutch release lever. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N.





- Secure slave cylinder with new bolt - arrow -.
- Insert transmission, making sure there is sufficient clearance to drive axles.





- Install engine/transmission securing bolts - arrow A - and - arrow B -.





- Install starter.





- Carefully lower transmission a short distance using engine/transmission jack V.A.G 1383 A.
- If possible, tighten upper engine/transmission securing bolts - arrows 1 - and - arrows 2 -.





- If installed, secure all electrical wiring to transmission again - arrows A to C -.





- If installed, install engine speed (RPM) sensor G28 on left side of transmission.





- Install selector shaft lever and tighten nut - arrow -.





- Install push rod - 1 -; by tightening hex socket-head bolt.
- Secure connecting rod - 2 - for selector rod.





- Connect electrical connector - arrow - for reversing light switch on transmission (right side).





- Lift transmission again using engine/transmission jack V.A.G 1383 A.
- Attach tunnel cross member to body with new bolts - 2 - and - 3 - (tighten hand-tight only).
- Secure tunnel cross member to transmission mounting - 4 -.
- Carefully lower engine/transmission jack V.A.G 1383 A and move it aside.
- Bolt drive axles - 1 - to flange shafts.





Cabriolet vehicles with 4-cylinder engine:

- Lift engine slightly using spindles.





- Tighten bottom engine/transmission securing bolts - arrows -.
- Lower engine back down.





- Secure torque reaction support - arrows -.





- Tighten nuts - 1 - for engine mountings.

Continued for all vehicles:

- Secure subframe and tunnel cross member.
- Install exhaust system and align stress free.
- Check selector mechanism setting and adjust if necessary.
- Check fluid level in transmission.
- Follow steps required after connecting battery.
- If necessary, carry out wheel alignment.

^ Wheel alignment is not necessary if subframe was located in relation to body using testing mandrel 3393 prior to disassembling and assembly of subframe (before tightening bolts).
^ Wheel alignment must, however, be perform if the subframe was not located in relation to body using testing mandrel 3393 or if it was not possible to fully insert two pins into holes.

Tightening torques

Note:
^ Tightening torques only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
^ Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant.
^ Do not use parts which have been degreased.
^ Tolerance for tightening torques ±15%.





Engine/transmission attachment (2.0 ltr. engine)





* With bracket for wiring harness
* Hammer head bolt with nut
* With nut