Removing and Installing

WARNING!
^ Do not re-use any fasteners that are worn or deformed in normal use.
^ Some fasteners are designed to be used only once, and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow the recommendations-replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.





Special Tools
The special tools and test equipment are necessary for this work:
10-222 A/4 Engine support
3180 - Hanging device
3282 - Transmission holder
VAG 1383 A - Lift
3282/19 - Adjusting plate

Removing

CAUTION!
^ Before disconnecting the battery Ground (GND) strap, determine the correct coding for the anti-theft radio.
^ Bolts that are connected to the body must be stored separately (danger of contact corrosion from uncoated bolts).

^ Switch ignition off.
^ Disconnect battery Ground (GND) strap.





^ Disconnect intake air duct between air cleaner housing and throttle.
^ Remove engine cover.
^ Remove upper engine/transmission connecting bolts.





^ Loosen mounting bolts (arrows) on fan shroud and electric fan (electric fan can be laid to side while still connected).
^ Disconnect connectors for heated oxygen sensors.
^ Remove upper mounting nuts from front exhaust pipe.





^ Disconnect connectors for left and right knock sensors on fuel rail.
^ Disconnect fuel rail and lay to side with injectors (close openings on engine with clean cloths).





^ Locate engine support 10-222A (together with adapter for 10-222 A/3 and 10-222 A/4) on bolts of strut mount. Attach mounting hooks to eyes on engine using brackets 3180 and take up weight of engine with spindle.

Notes:
^ The bracket 3180 and the threaded rod of holding device 10-222A are screwed in from the front on the left side and from the back on the right side.
^ The supports 10-222 A/1 must not be used.

^ Remove front wheels.





^ Remove noise insulation together with bracket.
^ Unclip air duct for generator.





^ Remove heat shields for right and left drive axles (arrows).
^ Loosen right and left drive axles from transmission and move forward.
^ Remove lower mounting nuts and bolts for front exhaust pipes and remove front pipes together with three way catalytic converters and heated oxygen sensors.
^ Remove cross member below exhaust system.
^ Disconnect rest of exhaust system and remove.





^ Loosen lower mounting bolts (arrows) on engine mounts.





^ Remove mounting bolts (arrows) on right front torque arm.
^ Raise engine until engine mount comes out of subframe.

CAUTION! Make sure that the throttle body does not damage the insulation liner on the bulkhead.





^ Remove right engine support and cable clamps (arrows).
^ Place engine mount on subframe.
^ Loosen lower engine/transmission bolts.





^ Disconnect wiring connections from starter as follows:
- Remove mounting bolt -1- for starter.
- Remove ground strap from engine block (starter ring).
- Disconnect wire -2-.
- Remove positive cable -3-.





^ Remove remaining mounting bolts from starter and bracket (arrows).
^ Remove upper mounting bolt from starter with extension and hang starter up to side on subframe.





^ Remove 3 bolts for torque converter through opening for starter (turn crankshaft 1/3 revolution further for each bolt).

Note: loosen the bolts for the torque converter, counter-hold the center bolt on the vibration damper.

^ Lower engine and install left engine mount on subframe.
^ Tighten lower mounting bolts slightly.





^ Remove rear bracket for noise insulation -1-.
^ Move safety lever -4- and disconnect connector for transmission wiring harness.
^ Disconnect connector for multi-function switch -2- and disconnect bracket for connector -3-.
^ Disconnect speedometer Vehicle Speed Sensor (VSS) -G22-.
^ Remove Engine Speed (RPM) Sensor -G28- from left front of transmission.
^ Remove lower engine/transmission connecting bolts.





^ Set up transmission holder 3282 together with adjusting plate 3282/19 (for automatic transmission 01V) and place on VAG 1383A lift.

Notes:
^ The symbols on the adjusting plate show the required brackets for the automatic transmission 01V. The arrow points in the driving direction.
^ The transmission can also be supported with the VAG 1383 A lift and the plate 135912.





^ Support transmission from below with VAG 1383 A lift and transmission bracket 3282.
^ Disconnect heat shield plate for selector lever cable from transmission.
^ Remove right and left transmission supports.
^ Remove multi-function switch to protect from damage.





^ Press ball socket of selector lever cable -1- from transmission selector lever -2-.





^ If necessary, mark position of mounting bracket for selector lever cable relative to transmission housing for reinstallation.
^ Remove mounting bracket bolts (arrows).





^ Remove bolts -1- and -2-.
^ Lower rear subframe (maximum 80 mm or 3.15 inch) from mounting point on body by releasing tension on engine support.
^ Lower rear of transmission a small distance.
^ Remove bracket for ATF line from engine (on left front) and remove ATF line from transmission.





^ Support engine at front with commercial support.





^ Press torque converter off flex plate of engine using pry bar.
^ Press transmission off engine.





^ Lower rear edge of transmission by adjusting bracket 3282 (arrow).
^ Guide transmission out diagonally (downward to rear).
Subframe is lowered by distance -a- (approximately 80 or 3.15 inch)

Notes:
^ If necessary, decrease tension on the spindle of the engine support 10-222 A.
^ Make sure there is enough clearance between the bulkhead and the engine.
^ Secure the torque converter so it will not fall out.

Installing

Notes: Before installing the transmission:
^ Make sure the torque converter is correctly installed in the transmission.
^ Make sure the dowel sleeves are correctly seated on the engine housing.

Before installing a replacement transmission, first clean the oil cooler and oil lines.

The transmission is installed in reverse order of removal. Pay particular attention to transmission .
^ Make sure that no hoses get pinched when engine and transmission are pushed together.
^ Use only original bolts to fasten torque converter to flex plate (M 10 x 1. 17).
^ If necessary, slide shim plate between front longmember and torque arm.
^ Always replace self-locking fasteners.
^ Always replace gaskets and O-rings.
^ Replace M14 bolts (and respective conical spring washers) for subframe.
^ Install subframe using appropriate tightening sequence.
^ Adjust selector lever cable.
^ Install exhaust system.
^ Check fluid level in final drive of automatic transmission.
^ Check ATF level.
^ Install drive axles.





Engine/Transmission mounting (Part 1 of 3)





Engine/Transmission mounting (Part 2 of 3)





Engine/Transmission mounting (Part 3 of 3)

Note: Dowel sleeves for alignment are at locations A and B.





Tightening torques (Part 1 of 4)





Tightening torques (Part 2 of 4)





Tightening torques (Part 3 of 4)





Tightening torques (Part 4 of 4)