4.2L FSI
Transmission, Installing
Special tools, testers and auxiliary items required
• Assembly Aid (T40169)
• Transportation Lock (T40170)
• Ring Spanner Insert AF16 (V.A.G 1332/14)
• Transmission Support (T40173)
• Engine/Transmission Jack (V.A.G 1383 A)
• Counterhold Tool Touareg V10 (T10172) with Adapter (T10172/5)
• Engine Support Bridge (10 - 222 A)
• Ring Spanner Insert AF 16 (V.A.G 1332/14)
Procedure
• Replace bolts that are tightened to the specification. The aluminum bolts for attaching the engine to the manual transmission may be used two times.
• Replace self-locking nuts and bolts and seals, gaskets and O-rings.
• The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps of the same type as those equipped by the factory, refer to the electronic parts catalog ETKA.
• When installing, bring all cable ties back to the same positions.
• Check the input shaft near the bearing in the drive plate - arrow - for scoring. Replace the needle bearing in the drive plate, if necessary.
Transmission Installation Tightening Specifications:
- Check if the alignment sleeves - A - for centering the engine/transmission are in the cylinder block and insert them if they are not.
• See if it is possible to use the aluminum bolts - 2 through 11 - again and mark them, if necessary.
- Install the clutch module, if necessary.
- Mount the transmission onto the (T40173) and secure it using the tension strap - 1 - as illustrated.
- The following preparations must be made before connecting the engine and transmission:
- Insert the (T40169) in the transmission housing and the clutch module from below as shown in the illustration.
• The (T40169) must engage in the semi-circular opening - 1 - and into the check hole - 2 -.
• There is only 1 inspection opening on the circumference. Rotate the clutch module as needed.
- Install the bolts from the (T40169) into the holes on the transmission housing.
- Insert the (T40170) in the transmission housing from below and secure it on the flange shaft - 1 -.
- Raise the transmission straight up until the clutch slave cylinder can be inserted.
- Tighten the bolt - 2 -. Tightening specification => [ (Item 17) Bolt ] Description and Operation.
• The next step is only necessary if a drive plate with alignment pins - 2 - are installed.
- Also align the drive plate to the clutch module so the alignment pins - 2 - on the drive plate (if applicable) can engage in the larger holes - 1 - on the clutch module.
The clutch will not function properly if it is not installed correctly.
• The clutch may have noticeable function problems if the alignment pins for the drive plate - 2 - are not in the holes in the clutch module - 1 -.
- Attach the transmission to the engine and tighten the bolts - 3 through 11 -.
- Install the starter and tighten the bolt - 1 - from the engine side. Tightening specification.
- Next, use tightening torque to tighten the bolt - 2 - from the transmission side.
- Raise the transmission using the (V.A.G 1383 A) until dimension - a - is reached between the subframe and the body.
• - a - = minimum 100 mm
- Install the left and right drive axles on the transmission flange shafts.
- Install the drive axle heat shield and tighten the bolts - arrows - to 23 Nm.
- Tighten the push rod - 1 -. Tightening specification => [ (Item 27) Bolt ] Selector Mechanism Overview.
- Connect the connector - 2 - to the transmission range gear recognition switch (F208).
- Attach the connecting rod - 3 -. Tightening specification => [ (Item 25) Bolt ] Selector Mechanism Overview.
- Install the transmission shift lever - 2 - as follows:
• The gearshift lever - 2 - can be attached to the gearshift shaft - 1 - in only one position (gap in the splines - arrow -).
- Attach the transmission shift lever - 2 -. Tightening specification => [ (Item 18) Nut ] Selector Mechanism Overview.
- Lift the transmission and tighten the tunnel crossmember bolts - arrows -. For the correct tightening specifications, refer to => [ Tunnel Crossmember, Transmission Mount and Transmission Support Overview ] Tunnel Crossmember, Transmission Mount and Transmission Support Overview.
- Remove the (V.A.G 1383 A) and (T40173).
- Mount or install the driveshaft on the transmission.
Tightening Sequence - Clutch Module to the Drive Plate
- Remove the (T40169) and (T40170).
- Put in sixth gear; to do this, move the gearshift shaft - 1 -, push the gearshift lever - 2 - forward in direction of - arrow -.
- Mount both front wheels.
Use the (T10172) and (T10172/5) to block the driveshaft to keep it from turning, too.
• The following step is absolutely necessary to make sure the clutch module rests on the drive plate evenly and is not tilted.
- Turn both front wheels together in one direction until the clutch module turns one complete turn (360°).
• The check hole - arrow - must be visible in the transmission housing cut-out.
Tighten the clutch module to the drive plate as follows:
• Use new bolts.
• Tighten the bolts using the (V.A.G 1332/14).
- Install the first bolt - arrow - and tighten by hand (2 Nm).
- Continue turning the clutch module/drive plate 180° via the front wheels.
- Insert the second bolt and tighten it to the specification.
- Insert the remaining connecting bolts connecting the clutch module to the drive plate and tighten them to the specification immediately (including the first bolt installed).
Install in reverse order of removal paying attention to the following:
- Tighten the universal joint on the steering gear.
- Mount the right catalytic converter to the exhaust manifold.
- Install the left and right front muffler.
- Install the exhaust system so that it is free of tension.
- Install the subframe crossbrace.
- Install the coolant connection.
- Install right coolant pipe.
- Install the rear coolant pipe.
- Gear oil level in manual transmission, checking. Refer to => [ Manual Transmission, Checking Transmission Fluid Level ] Service and Repair.
- Fill with coolant.
- Tighten down both front wheels using tightening torque.
- Install the noise insulation.
- Observe measures after connecting the battery.
There is a risk of destroying control modules with excess voltage.
• Do not use a charger as a starting aid.
Tightening Specifications
• The tightening specifications apply only to lightly greased, oiled, phosphated or blackened nuts and bolts.
• Additional lubricant such as engine oil or transmission fluid may be used, but do not use graphite lubricant.
• Do not use any ungreased parts.
• Tightening specification tolerance ± 15%.
Mounting 4.2L FSI Engine on Manual Transmission
Check the aluminum bolts - 2 through 11 - to see whether they can be reused.
• Audi A4 from VIN 8K-9-066500, Audi A5 from VIN 8T-9-008000: The aluminum bolts may be used twice. Therefore, a chisel must be used to mark the bolts with two notches that form an "X" after they have be used the first time - arrow -.
• To prevent damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt using a 14 mm socket with a 1/2 drive, which is inserted in to the vise, as illustrated.
• Bolts marked with an "X" may not be used again.
• Audi A4 through VIN 8K-9-066499: Always replace the aluminum bolts.
• Audi A5 through VIN 8T-9-007999: Always replace the aluminum bolts.
• There is no limit to the number of times the steel bolt can be used again.