Installing

Installing - 5 Spd. Automatic Transmission 01V

Installation is reverse of removal, noting the following:

Before installing:

All-wheel-drive vehicles

- Clean threads in driveshaft flange!

Continuation for all vehicles

- Clean ATF lines.
- Insert torque converter into transmission.

WARNING:
Check installation dimension of torque converter before installing transmission

- Make sure bushings are correctly seated.

Note:
If the bushings get stuck in the transmission housing, they must be removed and new bushings must be installed on the engine.

For 6 cylinder gasoline engines:
Item A = bushings

For 6 cylinder TDI engines
Item A = bushings

- Position 3282 transmission support.

Use 3282/19 adjustment plate to position the 3282 transmission support for Automatic Transmission 01V.

The symbols on the adjustment plate indicate the necessary mounts and the arrow points toward front of vehicle.

- Place transmission onto transmission support.

- Secure transmission on 3282 transmission support using bolt -A-.
- Move transmission into position between the lowered subframe and vehicle floor.

- Press the lever/shift rod -2- at transmission completely toward rear (toward right in illustration) until park lock is engaged.
- Shift selector lever into "P" and carefully press up ball head of selector lever cable on lever/shift rod -2- using a pair of pliers.
- If installed, press securing brace (arrow) open at end of selector lever cable.

Note:
Do not deform lever/shift rod when pressing up or else shifting cannot be precisely adjusted any more.

- Align transmission properly to engine.

Note:
^ If installed, place intermediate plate onto bushings.
^ Make sure that wires do not get pinched as transmission is docked at engine.

Check whether the torque converter is still properly installed and has not slid out of the converter housing toward the front:

- It must be possible to easily turn torque converter by hand without much force.

WARNING:
In case of an incorrectly inserted torque converter, the coupling plate of the torque converter or the ATF-pump will be destroyed, if the transmission is flanged to the engine.

- If the torque converter is difficult to move, check installation dimension once again.

For 6 cylinder TDI engines

- Check whether brace -B- is still swung to side (arrow direction) before installing the transmission.

Continuation for all vehicles

- Install connecting bolts for engine/transmission.

Note:
Some bolts also have a bracket or a Ground (GND) connection attached.

- Install multi-function Transmission Range (TR) switch -F125-.
- Slightly raise engine/transmission subframe at rear via VAG 1383 A hoist.
- Install remaining connecting bolts for engine/transmission.
- Install front exhaust pipes.
- Install subframe, observe tightening sequence and alignment with master hole.
- Only perform vehicle alignment if necessary.
- Install transmission supports at left and right with transmission mount.

- Remove bolt -A- after transmission is bolted to engine.
- Apply corrosion protection to contact surface between bolt -A- and oil pan.

Bolt torque converter to drive plate

For vehicles with hex bolts:

- Bolt torque converter to drive plate via 3 bolts using special tool V175 (turn crank shaft an additional 1/3 turn every time).

For vehicles with Torx bolts:

- Bolt 3 torque converter bolts to drive plate using respective Torx insert (turn crank shaft an additional 1/3 turn every time).
- Install starter.
- Install ATF lines to engine/transmission subframe.
- Install bracket for ATF- line.
- Slightly raise engine/transmission subframe at rear via VAG 1383 A hoist.

- Bolt in engine speed (RPM) sensor -G28- (arrow -B-) at front left of transmission (if installed).
- Connect connector for speedometer Vehicle Speed Sensor (VSS).
- Bolt drive axles to transmission flanges.

- Bolt in bolts at mounting bracket of selector lever cable, install selector lever cable and if necessary, adjust.

- Connect connector of multi-function Transmission Range (TR) switch -1-.
- Connect connector for transmission wiring harness and secure using securing lever -2-.
- Install shielding plate/selector lever cable

All-wheel-drive vehicles

- Bolt driveshaft to transmission flange.

- Bolt heat shield -B- for driveshaft to Torsen differential cover (arrows) if installed.
- Install heat shield -A- above driveshaft.

Continuation for all vehicles

- Install bracket for noise insulation panel.
- Install noise insulation panel.
- Install front wheels.
- Connect battery Ground (GND) strap.
- Check adjustment of selector lever cable.
- Check gear oil in final drive with transmission installed.
- Then check ATF level and top off.
- After connecting battery, enter anti-theft code for radio.
- Fully close power windows to stop.
- Then activate all power window switches ("up") for at least one second to activate automatic window raising/lowering.
- Set clock to correct time.

Removing and installing for 2.7 Liter 5V turbo engine:

- Remove bolts (arrows) and remove engine covers -A- and -B-.
- Remove cover above air filter.

- Remove coolant expansion tank (arrows) and lay to side.
- Disconnect connector for coolant level display.
- Remove cover from valve cover (cylinder bank 4-6).

- Remove air distributor (arrows).

- Remove heat sensor -1 - from right turbocharger using 3035.
- Remove heat shields -2- from left and right turbochargers.
- Remove upper bolts -3- to front line to left and right turbochargers.

- Disconnect connector -1- for oxygen sensor (right side) at bulkhead.
- Expose wire with connector to oxygen sensor.

- Disconnect connectors -2- of left oxygen sensor at bulkhead and remove lower part of connectors from bracket.
- Expose wire with connector to oxygen sensor.
- Remove all connecting bolts for engine/transmission which can be reached from the top.
- Assemble both 10-222A/3 engine support adapters for front and rear spindles on support bar.

- Set 10-222A engine support bridge onto the fender mounting flanges using 10-222A/1 brackets.
- Hang both spindles on the adapters.
- Secure engine to spindles. To do so, additionally use a shackle -1- at the rear side of the engine to avoid damage.
- Take up weight of engine/transmission assembly on spindles.
- Tighten the rear spindle less, to enable later lowering at rear.
- Raise vehicle.
- Remove front wheels.

- Remove sound-deadening pan.
- Remove bracket for noise insulation panel.

- Remove left and right heat shields for drive axles (arrows).
- Disconnect drive axles from transmission drive flanges.

- Unbolt engine speed (RPM) sensor -G28- (arrow B) from transmission at front left.
- Remove connector for speedometer (arrow -A-) from transmission.

- Disconnect connector -1- from wire for multi-function switch.
- Swing securing lever -2-, disconnect connector for transmission wiring harness.

- If necessary, remove A/C line from oil pan (arrow) for better access to the starter.

WARNING:
Do not open refrigerant circuit for A/C system.

For vehicles with the illustrated vertical headlight aim control system, repair notes must be observed before lowing subframe.

Otherwise the sensor may be destroyed.

- Loosen left and right transmission mounts from subframe.

- Mark installation positions for threaded assemblies -1- and positioning sleeves -2-.
- Remove nuts -1- on left and right engine mounts.

Note:
When installing, make sure that locating sleeves -2- engage again.

- Roll VAG 1383 A engine/transmission hoist with 3282 transmission support under transmission and support transmission.
- Align adjustment plate parallel to transmission.
- Secure transmission on 3282 transmission support using bolt -A-.

Automatic Transmission 0 IV with All Wheel Drive is supported at the same positions as the Front Wheel Drive version.

WARNING:
When working on the subframe, all precautions and notes which are listed must be must be observed.

- Before loosening carrier, special tool 3393 must be used to check whether holes -1 - and -2- line up.
- Completely lower subframe at rear and front.

- Mark installation position of protector shield and hose clamp -1- at left and right exhaust pipe using a waterproof marker, to quickly find the correct installation position when reinstalling.
- Remove hose clamp -1 - from left and right protector shield for turbocharger.
- Unbolt left and right exhaust pipes -2- from turbocharger.

- Remove heat shield -A- above driveshaft.
- Remove rear part of exhaust system if necessary.
- Remove heat shield -2- for driveshaft from cover for Torsen differential (arrows).
- Unbolt driveshaft from transmission and hang or support.

- Mark position of mounting bracket for selector lever cable to transmission housing for re-installation, unbolt mounting bracket (arrows).

- Pry off selector lever cable from lever/shift rod using 80-200 (arrows).

Removing 3 torque converter bolts

- Remove plug above opening -A- in engine flange.
- Remove torque converter bolts from drive plate via opening -A- in engine flange (turn crankshaft 1/3 rotation each time).

If opening -A- is not present, perform the following two work steps to be able to remove the 3 bolts of the torque converter.

- Remove starter.

- Remove torque converter from drive plate by removing 3 bolts using special tool V175 (turn crank shaft an additional 1/3 turn every time).

- Remove bolt -9- with bracket -12-.
- Disconnect ATF lines at bolts -10- and -11- and plug the lines with clean plugs
- Loosen nut -3- with bracket -4- in order to prevent tension when removing and installing.
- Remove remaining connection bolts for engine/transmission.
- Press transmission off engine, while pressing torque converter out of drive plate.

- Press torque converter against the ATF pump (arrow).

- Rotate transmission (arrow) and carefully move into position between subframe and vehicle floor.
- Lower transmission.
- Secure converter so it does not fall out.

Installing

Installation of transmission is the reverse of removal. The following points must also be observed:

Before installing:

- Clean threads in driveshaft flange using a tap.
- Clean ATF lines.
- Insert torque converter into transmission.
- Make sure bushings are correctly seated.

Note:
If the bushings get stuck in the transmission housing, they must be removed and new bushings must be installed on the engine.

For 2.7I 5V turbo engines

Item A = bushings

- Secure transmission on 3282 transmission support using bolt -A-.
- Move transmission into position between the lowered subframe and vehicle floor.

During this, the subframe is lowered approx. 150 mm at rear, illustration A37-0067.

- Align transmission properly to engine.

Do not deform lever/shift rod when pressing up or else shifting cannot be precisely adjusted any more.

Note:
^ Place intermediate plate onto bushings.
^ Make sure that wires do not get pinched as transmission is docked at engine.

Check whether the torque converter is still properly installed and has not slid out of the converter housing toward the front:
- It must be possible to easily turn torque converter by hand without much force.

WARNING:
In case of an incorrectly inserted torque converter, the coupling plate of the torque converter or the ATF-pump will be destroyed, if the transmission is flanged to the engine.

- If the torque converter is difficult to move, check installation dimension once again.
- Install connecting bolts for engine/transmission.

Note:
Some bolts also have a bracket or a Ground (GND) connection attached.

- Install bolts of torque converter through opening -A- in engine flange to the drive plate (turn crankshaft 1/3 rotation each time).
- Insert plug into opening -A- in engine flange.
- Install subframe, observe tightening sequence and alignment with master hole.
- Only perform vehicle alignment if necessary.
- Install transmission supports at left and right with transmission mount

- Remove bolt -A- after transmission is bolted to engine.
- Apply corrosion protection to contact surface between bolt -A- and oil pan.
- Bolt on ATF lines
- Bolt drive axles to transmission flanges.
- Bolt driveshaft to transmission flange.
- After connecting battery, enter anti-theft code for radio.
- Check adjustment of selector lever cable.
- Check gear oil in final drive with transmission installed.
- Then check ATF level and top off.
- Fully close power windows to stop.
- Then activate all power window switches ("up") for at least one second to activate automatic window raising/lowering.
- Set clock to correct time.