Golf/GTI (From 2010) With A Gas Engine
Transmission, Installing
• Refer to "Transmission, Removing" to get a list of the special tools needed. Refer to => [ Transmission, Removing ] Transmission, Removing.
• Replace the self-locking nuts and bolts.
• Replace the bolts that were tightened to an additional torque angle.
• Install any cable ties that were loosened or cut off during removal at their same location.
• Clean the input shaft splines and (on a used clutch disc) the hub splines. Remove any corrosion and then apply a very thin coat of grease for clutch plate splines (G 000 100) to the splines. Then move the clutch disc back and forth on the input shaft until the hub moves freely on the shaft. Excess grease must be removed.
- If the transmission is replaced, transfer the transmission shift lever and the relay lever.
- Clean all threaded holes for self-locking bolts with a thread tap to remove any locking fluid residue.
- Check whether there are alignment sleeves for the transmission in the cylinder block; install if necessary.
If the alignment sleeves are missing, it will be difficult to shift, there will be clutch problems and the transmission may make noises (loose rattling).
- Make sure the intermediate plate is engaged on the sealing flange and pushed onto the alignment sleeves - arrows -.
- Check the release bearing for wear. If necessary, replace the slave cylinder and the release bearing. Refer to => [ Slave Cylinder with Release Bearing ] Service and Repair.
- Install the bracket (T10346) with a bolt - 1 - in the left threaded hole in the subframe.
- Install the bracket (T10346) in the same angled position as the engine.
Bolt - 1 - = M6 x 20 collar bolt
- Secure the engine support device (3300 A) to the bracket (T10346).
- Push the engine forward using the spindle on the engine support device (3300 A). Note the following when doing this:
• The Air Conditioning (A/C) compressor - 2 - must not touch the refrigerant line - 1 - - arrow -.
• The generator must not touch the refrigerant line.
• The pressure pipe must not touch the radiator.
To install the transmission, the adjustment plate (3282/33) must be installed on the transmission support (3282).
- Align the arms of the transmission support so that they match up with the holes in the adjustment plate.
- Install the support elements - A - as illustrated on the adjustment plate.
- Install the pins (3282/29) in place on the adjustment plate.
- Place the transmission on the engine-/gearbox jack (V.A.G 1383 A).
- Align the adjustment plate so that it is parallel to the transmission.
- Install the pin (3282/29) into the hole on the transmission for the pendulum support bolt.
- Install the adapter (VW 771/40) in the threaded hole in the transmission housing as illustrated.
- Secure the transmission to transmission support (3282) using a bolt (MD) - A -.
The arm - B - must be flush with the guide on the transmission support (3282) - arrow -.
- Place the engine-/gearbox jack (V.A.G 1383 A) under the vehicle. The arrow points in the direction of travel.
• Pay attention to the lines when installing the transmission.
- Rotate the transmission in the - direction of the arrow - near the differential using the spindles on the transmission support (3282).
- Lift the transmission carefully.
- Move the transmission using the spindles on the transmission support (3282) into an angled position.
- Guide the transmission and the differential over the subframe - A - in the - direction of the arrow -.
- When doing this, be careful of the longitudinal member - arrows -
- Move the transmission toward the rear to the subframe.
• After that, the right flange shaft - 1 - must be guided past the flywheel and the cut out - arrow - in the intermediate plate.
- Turn the transmission into it installed position using the spindles on the transmission support (3282).
- Line up the transmission and the engine and install it.
- Insert the engine to transmission bolt - C - and tighten it to specification. Refer to => [ Tightening Specifications ] 02Q Manual Transmission.
- Install the engine to transmission bolt - arrow - and tighten it to specification. Refer to => [ Tightening Specifications ] 02Q Manual Transmission.
- Remove the engine support device (3300 A) and the bracket (T10346).
- Install the lower engine to transmission bolts and tighten them to specification. Refer to => [ Tightening Specifications ] 02Q Manual Transmission.
- Remove the transmission support (3282) after the transmission is bolted to the engine at the bottom.
- Install the upper engine to transmission bolts and tighten them to specification. Refer to => [ Tightening Specifications ] 02Q Manual Transmission.
- Install the transmission shift lever to the gear shift shaft, refer to => [ Installing the Transmission Shift Lever ] Shift and Selector Cables Overview and tighten the nut to specification, see - item 17 - in the => [ Shift and Selector Cables Overview ] Shift and Selector Cables Overview.
- Install the relay lever with the cable retainer. Refer to => [ Plastic Relay Lever ] Plastic Relay Lever.
- Install the transmission mount bracket - 1 - to the transmission using new bolts - arrows - and tighten them to specification. Refer to => [ Tightening Specifications ] 02Q Manual Transmission.
- Align the engine/transmission in its installed position. Lift it until the transmission mount bracket - 1 - is in complete contact with the transmission mount - 2 -.
- Secure the transmission mount - 2 - to the transmission mount bracket with new bolts - arrows - and tighten them to specifications. Refer to => [ Tightening Specifications ] 02Q Manual Transmission.
• Install the transmission mount free of tension.
Only remove the engine support bridge (10-222 A) when all the transmission mount/bracket bolts are tightened to specification.
- Install the flywheel cover plate - A - and bolt - arrow - (if equipped). Refer to=> [ Tightening Specifications ] 02Q Manual Transmission.
• There are threaded inserts (for example a "Heli-Coil(R)") in the pendulum support bolt holes.
• How to recognize: Shoulder - arrow - at the first thread.
• Be sure to use the correct bolts and tightening specification.
- Install the pendulum support.
• Install the transmission mount free of tension.
- Assemble the exhaust system.
- Install the drive axles.
- Install the drive axle heat shield and bolts - arrows -, if equipped.
- Install the left coupling rod.
- Install the left front level control system sensor to the control arm, if equipped.
- Install the fan shroud - arrow - and fans.
- Install the charge air hose, secure the clips - arrows 1 and 2 -, then connect the charge air pipe to the engine.
- Install the starter and tighten the lower bolt.
- Attach the bracket for the lines to the lower starter bolt.
- Install the top bolt on the starter and attach the connectors and the cables to the starter.
- Attach the ground strap - 1 - to the top starter bolt.
- Connect the connector - 2 - to the backup lamp switch.
- Push the hose/line assembly or pipe - A - into the breather assembly/slave cylinder to the stop and push the clip - arrow - downward.
- Pull on the line to make sure it is secure.
- Remove the hose clamp up to 25 mm dia. (3094) from the hose/line assembly or supply hose.
- After removing the hose clamp up to 25 mm dia. (3094) , bring the supply hose back to its original shape.
- Bleed the clutch system. Refer to => [ Clutch System, Bleeding ] Procedures.
- Make sure the vacuum hose for the brake system is installed correctly.
- Install the cable bracket to the transmission and tighten the bolts/nut - arrows - to specification, see - items 6 and 10 - in the => [ Shift and Selector Cables Overview ] Shift and Selector Cables Overview.
- Insert the selector cable into the cable retainer.
- Apply a small amount of grease to the pin - arrow - on the transmission shift lever - 2 -.
Grease allocation, refer to the Parts Catalog.
- Replace the lock washer - 1 - after every disassembly.
- Adjust the shift mechanism. Refer to => [ Shift Mechanism, Adjusting ] Adjustments.
- Install the battery tray and the battery.
- If removed, install the air filter housing.
- Install the plenum chamber cover and seal.
- Install the foam pieces to the upper edges of the left and right fenders.
- Install the engine cover if necessary.
- Connect the battery and then complete the steps after connecting the battery.
- Check the transmission fluid level. Refer to => [ Transmission Fluid, Checking ] Service and Repair.
- Install the lower section of the left front wheel housing liner..
- Install the noise insulation.
- Check the headlamp adjustment if the vehicle has a left front level control system sensor.