Transmission, 4-Cylinder, Removing
Transmission, 4-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)
• Grease for Clutch Disc Shaft Splines (G 000 100 )
• Copper Grease (Z 381 351 TE)
Procedure
• 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 -.
Vehicles with 1.8L turbo engine:
- Remove engine cover - arrows -.
Vehicles with 2.0L turbo engine:
- Remove engine cover - arrows -.
All Vehicles
- Remove the upper engine/transmission bolts - arrow 1 - and - arrow 2 -. When doing this, make sure the bracket for the wires and coolant pipe is under the bolts - arrows 2 - (this is important for installing).
- 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.
- Position Engine Support Bridge (10-222 A) with Adapters (10-222/3) on to bolted flanges of fender.
- Engage spindles onto engine lifting eyes as shown.
- Pre-tension engine slightly with spindles.
- 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 - arrow -.
- Remove right drive axle heat shield - arrow -.
- Remove the left and right drive axle from the transmission flange shafts.
Make sure drive axle protective coating is not damaged.
- Remove bolt - 1 - and nut - 2 - and remove the front exhaust pipe bracket, where applicable.
• Do not bend the flex joint in the front exhaust pipe more than 10°, otherwise it will be damaged.
• Disconnect the exhaust system at the clamping sleeve - arrow - and slide the sleeve to the rear.
- Tie up the front exhaust pipe to the side.
- Remove the driveshaft heat shield - 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.
Cabriolet:
• So that the three engine/transmission connecting bolts at bottom can be removed on the Audi Cabriolet, perform the following steps:
- Remove torque support - arrows -.
- Remove the nuts on the right and left sides - 1 - and then lower stabilizer bar - 2 -.
- Remove the nuts - 3 - on the left and right engine supports until lower edge of the nut is flush with threaded bolts - arrow -.
- Lift engine with Engine Support Bridge (10 - 222 A) up until nuts - 3 - come in contact with lower left and right of console.
All Vehicles
- Remove the three lower engine/transmission bolts - arrows -.
Cabriolet:
- Lower engine again.
All Vehicles
- 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 01X 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 the bolt - right arrow - to 20 Nm.
- Secure the right support pieces on the transmission as illustrated. Tighten the bolt - left arrow - to 20 Nm.
- Remove the bolts - 1 - and then the bolts - 2 -.
- Remove nuts - arrows - and remove tunnel crossmember.
- Lower the transmission using the Engine/Transmission Jack (V.A.G 1383 A) just a little.
- Disconnect electrical connector - arrow - on the Back-Up Light Switch (F4) and uncover electrical wire.
- Remove selector rod connecting rod - 2 -.
- Remove push rod - 1 - by removing the bolt using an 8 mm socket.
- Remove nut - arrow - and remove the selector shaft lever from the selector shaft.
- 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.
- Remove the clips/cable tie with the oxygen sensor wires on top of the transmission, where applicable.
- 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 installed to the new one - arrows - => [ Tightening specifications ] Service and Repair.
Installing transmission. Refer to => [ Transmission, Installing ] Transmission, Installing