engine AUDI A4 1999 B5 / 1.G 01W Transmission Remove And Install User Guide

34-31

Installing

Installation is the reverse order of removal, note
the following:

- Clean input shaft splines and (in case of used
clutch plates) hub splines. Remove corrosion
and apply only a very thin coating of lubricant G
000 100 on splines. Do not grease guide sleeve.

- Check throwout bearing for wear and replace if
necessary.

- Before installing, coat contact surface of clutch
release lever plunger with thin layer of copper
grease, e.g. Z 381 351 TE.

- Threaded holes for mounting clutch slave
cylinder to transmission and shift lever to shift
rod must be cleaned of locking compound
residue using threaded tap before installation.

- Make sure centering sleeves for engine to
transmission are installed correctly in cylinder
block. Install or replace if necessary.

- Always replace self-locking nuts.

-
Install engine/transmission intermediate plate (if
Pa
ge 14 of 20 Transmission, removin
g and installin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.34.2

present) onto engine centering sleeves.

- Make sure intermediate plate is correctly seated
on engine.
Pa
ge 15 of 20 Transmission, removin
g and installin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.34.2

34-32


Repair Manual, Electrical Equipment, Repair Group 27

Repair Manual, Engine Mechanical, Repair Group 26
Radio Operating Manual - Lift transmission until clutch slave cylinder with mounting bracket for
line/hose can be installed (arrow).
- Install lower engine/transmission and starter mounting bolts and install
starter.
- Check adjustment of shift mechanism and adjust if necessary Page
34
-12
.
- Align exhaust system free of stress.- Check transmission oil level Page 34
-36
.
- 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 a second to
activate automatic window raising/lowering.
- Set clock to correct time.
Pa
ge 16 of 20 Transmission, removin
g and installin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.34.2

34-33

Tightening torques

Transmission to engine (4-cylinder)
A: Dowel sleeves Item No.
Bolt
Tightening torque
1, 3, 4 M12 x 67 65 Nm (48 ft lb)
2, 6 M12 x 90 65 Nm (48 ft lb)
5, 11 M12 x 110 65 Nm (48 ft lb)
7 - 10 M10 x 45 45 Nm (33 ft lb)

Transmission/engine assembly mount (4-cylinder) Item No.
Bolt
Qty.
Tightening torque
1 M10 x 30 3 40 Nm (30 ft lb)
2 M10 x 35 1 50 Nm (37 ft lb)
3 M8 x 20 2 23 Nm (17 ft lb)
Pa
ge 17 of 20 Transmission, removin
g and installin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.34.2

34-34


Transmission to engine (6-cylinder)
A: Dowel sleeves Item No.
Bolt
Qty.
Tightening torque
1 M12 x 67 3 65 Nm (48 ft lb)
2 M12 x 90 1 65 Nm (48 ft lb)
3 M12 x 80 1 65 Nm (48 ft lb)
4 M10 x 45 3 45 Nm (33 ft lb)
5 M10 x 135 1 45 Nm (33 ft lb)
51) M12 x 130 1 65 Nm (48 ft lb) 1) Upper starter bolt

Transmission/engine assembly mount (6-cylinder) Item No.
Bolt
Qty.
Tightening torque
1 M10 x 35 3 40 Nm (30 ft lb)
2 M8 x 20 2 23 Nm (17 ft lb)
Pa
ge 18 of 20 Transmission, removin
g and installin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.34.2

34-35

Component

Tightening
torque
Drive axle to flange
shaft M8 40 Nm (30 ft
lb)

M10 77 Nm (57 ft
lb)
Engine Speed (RPM) sensor -
G28- 10 Nm (7 ft
lb)
Clutch slave cylinder to
transmission
Socket-head bolt 1) 20 Nm (15 ft
lb)
Bolt 2) 25 Nm (18 ft
lb)
Heat shields over drive axles to
transmission 23 Nm (17 ft
lb)

Shift rod to transmission 1) 20 Nm (15 ft
lb)
Pivot rod to transmission 40 Nm (30 ft
lb)
Three Way Catalytic Converter
(TWC) to mounts 25 Nm (18 ft
lb)
Front exhaust pipe to
turbocharger or exhaust 25 Nm (18 ft
lb)
Pa
ge 19 of 20 Transmission, removin
g and installin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.34.2