Gearbox installation (front-wheel drive vehicles) (VW Tiguan 1)

Instructions: Replace the self-locking nuts and bolts. Replace the bolts/screws that are tightened by turning them at a certain angle. During the work, it is necessary to reinstall all cable ties that were removed or cut off during dismantling. Clean the splines of the input shaft and, if using a used clutch disc, also the splines of its hub, remove traces of corrosion and apply a very thin layer of plastic grease for clutch disc splines - G 000 100- to the splines. Then, move the clutch disc along the input shaft until its hub slides freely. Be sure to remove excess grease.

When replacing the gearbox, transfer the gear engagement and selection levers together with the cable fasteners to the new unit. All threaded holes into which the self-locking bolts/screws were screwed must be cleaned with a tap from the remains of the thread locking compound. Check whether the centering bushings are inserted into the cylinder block (for correct alignment of the engine and gearbox). Without centering bushings, gear shifting becomes difficult, the clutch does not work well and noise may occur (gears rotating freely on shafts make noise). Make sure the adapter plate is installed and the "arrow" centering bushings are inserted.

check the clutch release bearing. Replace the worn bearing together with the slave cylinder. Mounting bracket "3282" is adjusted for installation of the "0A6" gearbox using the installation template -3282/60-. Install mounting bracket "3282" on the jack for engines and transmission units -VAG 1383 A-. Align the paws of the mounting bracket with the holes in the installation template. Screw in the grips "A" as shown on the installation template. Screw in grip-C- = pin -3282/34-. Install the gearbox on the jack for engines and transmission units -VAG 1383 A-.

Align the installation template parallel to the gearbox. Install the engine and transmission jack -VAG 1383 A- under the vehicle; the arrow on the installation template indicates the direction of vehicle movement.

After this, screw the pin -3282/34- into the hole for the bolt for fastening the lower support of the power unit on the gearbox. Using the lead screws of the mounting bracket "3282", tilt the gearbox to the left.

After this, carefully lift the gearbox without touching the side member.

Instructions: When lifting the gearbox, be careful not to damage the pipes and wires.

Using the lead screws of the mounting bracket "3282", install the gearbox into the mounting position.

Align the gearbox with the engine and install the gearbox on the centering bushings.

Screw in the lower bolts securing the gearbox to the Strelka engine and tighten them to the specified torque. Screw in the bolts securing the gearbox to the Strelka engine and tighten them to the specified torque. When the gearbox is bolted to the engine from below, remove the mounting bracket "3282" from it. Bring the power unit to the mounting position. To do this, lift the power unit so that the gearbox is fully adjacent to the left support of the power unit.

Screw in the new "arrow" bolts securing the left powertrain support and tighten them to the prescribed torque.

CAUTION: Disconnect the crossmember -10-222 A- only after all the power unit support mounting bolts have been tightened to the specified torque.

Screw in the upper bolts securing the gearbox to the "arrow" engine and tighten them to the specified torque. Install the starter "3". Connect the connector "2" to the reversing light switch "F4".

Attach the ground wire "1" to the gearbox.

If there is a clamp "1", secure the ground wire with a nut "2".

Replace the retaining ring "arrow A" and the sealing ring "arrow B" on the splined axle shafts. Lubricate the splines of the axle shafts with grease -G 000 100-. Install the drive shafts.

If equipped, install the drive shaft heat shield (bolts -1-) onto the engine. Install the subframe/wishbones, lower powertrain mount and steering gear.

Install the lower support of the power unit, bolts "1" and "2". Assemble the exhaust system and install the bracket of the system on the subframe.

If available, install the front ground clearance sensor "arrows".

Install the boost air hose "arrow 1" and "arrow 2", insert the pipe "A" into the tee of the working cylinder until it stops and press in the clamp "arrow".

The original can be seen on the portal (www.VWMANUAL.ru)

Check the reliability of the connection by pulling on the pipe.

Remove clamp "3094" from the hose. After removing clamp "3094" from the hose, return the hose to its original shape if necessary. Bleed the clutch hydraulic drive.

Screw in the bolts securing the "arrow" of the drive cable support bracket to the gearbox and tighten them to the specified torque. Install the "2" gear engagement lever and tighten its mounting nut to the specified torque.

Apply a small amount of grease -G 000 450 02- to the "arrow" pin of the gear selector lever "2". Connect the gear selector cable, use a new lock washer "1" after each removal. Install the gear selector lever assembly with the cable mount. Adjust the gearshift mechanism. Install the battery, bracket and casing.

Install the air filter housing assembly, if it was removed. Install the engine cover, if it was removed. Connect the battery and then perform the necessary work. Check the oil level in the gearbox. Screw on the front left wheel arch liner. Install the noise-insulating cover. Install the wheels. In vehicles with a front ground clearance sensor, check the headlight adjustment.