Transmission, 6-Cylinder, Removing
Transmission, 6-Cylinder, Removing
Special tools, testers and auxiliary items required
• Engine Support Bridge (10 - 222 A)
• Transmission Support (3282)
• Adjustment Plate (3282/43)
• Torque Wrench (V.A.G 1331)
• Torque Wrench (V.A.G 1332)
• Engine/Transmission Jack (V.A.G 1383 A)
• Fender Insert Pads (T40045)
• Lifting Tackle (2024 A)
• Grease for Clutch Disc Shaft Splines (G 000 100 )Copper Grease (Z 381 351 TE)
• All cable ties that are opened or cut open during removal must be replaced in the same positions during installation.
• Heat shield sleeves removed during removal should be placed in the same location when installing.
CAUTION!
Observe procedures for disconnecting battery.
- With the ignition switched off, disconnect battery Ground (GND) cable - arrow -.
- Remove rear engine cover - arrows -.
- Remove front engine cover - arrows -.
- Remove left cover - 1 - in engine compartment.
- Remove coolant reservoir - arrow -.
- Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch (F 66) at bottom of the reservoir.
- Tie the coolant reservoir with the hoses still attached - 1 -, - 2 - and - 3 - to the side.
- Remove right cover - 1 - in engine compartment.
- Remove the bolts - arrows - for the solenoid valve plate - 3 -.
- Remove air intake hose - 1 - at Mass Air Flow (MAF) Sensor.
- Disconnect crankcase ventilation hose - 4 - from air guide - 2 -.
- Remove the bolt - arrow - and disconnect the air guide - 2 - from the Throttle Valve Control Module.
- If installed, disconnect hose - 1 - from air duct.
• The illustration shows the air duct from rear with engine removed.
- Remove engine/transmission connecting bolts accessible from above.
- Disconnect the connectors - 1 through 4 - from the left bracket on the bulkhead.
- Disconnect the connectors - 1 - and - 4 -.
- Free up oxygen sensor wiring.
- Remove connector bracket.
- Remove nut - 1 - which is accessible from top for left exhaust pipe/exhaust manifold.
• Shown in illustration with engine removed.
- Remove sealing rubber on bolted fender flanges.
- To prevent damage to fender edges when using Engine Support Bridge (10-222 A), insert Fender Insert Pads (T40045) on both sides between bolted fender flange and web plate lying beneath.
- Place Engine Support Bridge (10 - 222 A) on bolted fender flange.
- Remove eyelet for Engine Sling (2024 A).
- Install the bolt - 1 - into the center hole of the Engine Sling and secure it with a cotter pin.
- Engage the Engine Sling (2024 A) bolt to the spindle in the Engine Support Bridge (10 - 222 A).
- Engage the Engine Sling (2024 A) into the front and rear lifting eyes on the engine.
CAUTION!
The hooks and pins on the Engine Sling (2024 A ) must be secured with plug connectors - arrows - as illustrated.
- Lightly pretension the engine with the Spindle on the Engine Sling.
- Loosen screws or quick-release connectors - 1 - and - 2 - and remove front noise insulation - A -.
- If equipped, loosen quick-release connectors - 3 - and remove rear noise insulation - B -.
- Remove noise insulation bracket - arrows -.
- Remove left and right drive axle heat shields - arrow -.
- Remove the drive axles from the flange shafts and tie up the drive axles.
• Make sure drive axle protective coating is not damaged.
- Remove front tunnel cross brace, where applicable - 1 through 4 -.
- Disconnect exhaust system at double clamps - arrows -.
- Remove the left front exhaust pipe and catalytic converter.
- Remove the bracket for the right front exhaust pipe from the transmission.
- Remove driveshaft heat shield, where applicable - arrows -.
- Remove bolts - arrows - at transmission/driveshaft flange.
- Push driveshaft toward rear final drive. CV joints can be moved axially.
- Tie up the driveshaft to the side.
- Remove nuts - 1 - at bottom on left and right engine mounts.
- Unclip the Level Control System Sensor (G78) rod on the lower control arm - arrow -.
- Before loosening subframe, check with Testing Mandrels (3393) whether holes - 1 - and - 2 - align.
If this is not the case, vehicle alignment must be carried out after installing subframe.
- First remove front bolts - 2 - and - 3 - at left and right subframe. Then remove bolts - 1 -.
- Lower front subframe.
- Remove lower engine/transmission bolts - arrows -.
- Initially re-tighten subframe.
Initial tightening specification:
1 approximately 100 Nm
2 approximately 70 Nm
3 approximately 70 Nm
CAUTION!
Bolts are replaced after installing transmission and tightened to final torque specification.
- Remove selector rod connecting rod - 2 -.
- Remove push rod - 1 - by unbolting socket head hex bolt.
- Disconnect electrical connector - arrow - on the Back-Up Light Switch (F4) and uncover electrical wire.
- Remove nut - arrow - and remove the selector shaft lever from the selector shaft.
- Remove Engine Speed (RPM) Sensor (G28) on left of transmission - arrow - and lay to side, where applicable.
- Remove starter from engine/transmission and secure if necessary.
• It is not necessary to disconnect the starter cable.
- Make a 10.2 mm dia. hole - arrow - in the support pieces in the Transmission Support (3282).
- Position Transmission Support (3282) for removing manual transmission 02X AWD with Adjustment Plate (3282 /43) and place on Engine/Transmission Jack (V.A.G 1383 A).
• The Adjustment Plate (3282/49) - arrows A - and (3282/52) - arrows B - are represented figuratively on the Adjustment Plate, the arrow points in direction of travel.
• Adjusting Plate only fits in one position.
- Align adjustment plate parallel to transmission.
- Secure support pieces at left of transmission as shown in illustration. Tighten M10x20 bolt - right arrow - to 20 Nm.
- Secure support pieces at right of transmission as shown in illustration. Tighten M10x20 bolt - left arrow - to 20 Nm.
- First remove bolts - 1 - and then bolts - 2 - on tunnel crossmember.
- Remove nuts - arrows - and remove tunnel crossmember.
- Remove remaining engine/transmission bolts - arrow A - and - arrow B -.
- Press transmission out of alignment sleeves and carefully lower with Engine/Transmission Jack (V.A.G 1383 A) until clutch slave cylinder is accessible.
• When lowering the transmission, make sure the hydraulic line to the clutch slave cylinder is not damaged.
- Remove clutch slave cylinder from transmission - arrow - and secure with wire, do not open wiring system.
CAUTION!
Do not press clutch pedal after clutch slave cylinder has been removed. Beyond a pedal force of approximately 300 N, clutch slave cylinder is destroyed.
- Open the cable tie - arrows A and B -, unclip the oxygen sensor wire - arrow C - and free up the wire.
- Lower the transmission.
• Pay attention to drive axle clearance when lowering.
- Secure the transmission with the Holding Fixture (VW 540) to the Assembly Stand. Refer to => [ Transmission, Securing to Assembly Stand ] Transmission, Securing to Assembly Stand.
- If the removed transmission is replaced, the transmission supports of the old one must be fitted to the new one - arrows - => [ Tightening specifications ] Service and Repair.
Installing transmission. Refer to => [ Transmission, Installing ] Transmission, Installing