Operation CHARM: Car repair manuals for everyone.

Part 2






S-Tronic Transmission

Engine, Removing

Vehicles with a Bolted Driveshaft






- Remove the driveshaft from the transmission.

- Slide the driveshaft toward the rear final drive; the CV joints can move axially.

- Secure the driveshaft to the side.

Vehicles with an Attached Driveshaft

- Remove the driveshaft.

All Vehicles






- Remove the steering intermediate shaft from the steering gear push them upward.

Prepare Scissor Lift Platform






- Equip the (VAS 6131 A) with the (VAS 6131/10) , (VAS 6131/11) and (VAS 6131/13) as follows:






- Next secure mounting elements to scissor lift table by hand.

- Position the (VAS 6131 A) horizontally.

Note bubble level (sight glass) on support platform.

- Move the (VAS 6131 A) under the engine/transmission subassembly.








The subframe could cause an accident if it is not secured.

Do not loosen the subframe bolts - 2 and 3 -.

- Remove the left and right subframe bolts - 1 -.

- Attach the mounting elements from the (VAS 6131/10) and (VAS 6131/13) at the left and right front of the subframe as shown in the illustration.






- Ensure threaded spindles are completely installed.

- Attach the mounting elements from the (VAS 6131/10) at the left and right rear on the subframe cross brace front connecting points as shown in the illustration.






- Attach mounting elements from the (VAS 6131/13) at the lower left and right of the wheel bearing housing as shown in the illustration.






- Attach the mounting elements from the (VAS 6131/10) and (VAS 6131/11) at the left and right rear of the tunnel crossmember as shown in the illustration.






- Rotate the mounting element spindles upward until all the mounting pins come into contact with the mounting points.

- Attach mounting element base plates to (VAS 6131 A) and tighten to 20 Nm.

- Mark the location of the subframe and engine carrier to the longitudinal members using a felt-tip pen.






- Remove the left and right subframe bolts - 2 and 3 - in a diagonal sequence in stages.

- Remove the bolts - arrows - on the tunnel crossmember.






- Remove the left and right bolts - 2 -.






Risk of damaging hose and wiring connections as well as engine compartment.

Make sure all the hoses and lines between the engine, transmission, subframe and body have been disconnected.

Carefully guide engine-transmission assembly with subframe out of engine compartment while lowering.

- Next lower engine/transmission subassembly with (VAS 6131 A) only by dimension - a -.






Dimension - a - = 100 mm maximum.

- Remove the ball socket - 2 - on the selector lever cable from the selector shaft lever using the (80 - 200).






- Press the securing clips - 1 - off and remove the selector lever cable from the transmission.

Do not bend or kink the selector lever cable.

- Lower the engine/transmission subassembly more.

- Remove the (VAS 6131 A) with the engine/transmission subassembly under vehicle.

Transmission, Separating from Engine

Special tools, testers and auxiliary items required

Scissor Lift Table (VAS 6131 A)

Support Set (VAS 6131/10) , Supplementary Set (VAS 6131/13-7) and Transmission Support (VAS 6131/14)

Socket (T40058)

Procedure






Engine/transmission assembly removed and placed on (VAS 6131 A).

- Remove the electrical connector - 3 - for the Oxygen Sensor (O2S) 2 after catalytic converter (G131) from the bracket and disconnect it.

Ignore - 1 and 2 -.

- Remove the bolt - 1 - and the nuts - arrows - and then remove the left catalytic converter.






- Remove the connector - 1 - for the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) (G130) from the holder and disconnect it.






- Remove the bolt - 3 - and move the bracket to the side.

Ignore - 2 -.

- Remove the bolt - 1 - and the nuts - arrows - and then remove the right catalytic converter.






- Disconnect the connector - 2 - from the Engine Speed (RPM) sensor (G28).






Ignore - 1 -.

Vehicles with Electro-Mechanical Power Steering






- Release the safety catch - arrow -, push the retainer down and disconnect the connector from - 2 - from the power steering control module (J500).

- Free up the wiring harness.

Ignore - 1 -.

All Vehicles






There is a risk of destroying the transmission control module (Mechatronic) with static discharge.

Do not touch contacts in the transmission connector with hands.

- To discharge static electricity, touch the transmission housing (without wearing gloves).

- Turn the twist lock counter-clockwise - arrow - and disconnect the connector from the transmission.

- Free up the wiring harness on the transmission.

- Remove the left and right drive axles from the transmission flange shafts.






- Remove the lower cover - 1 - from the transmission - arrow -.






- Insert the (T40058) guide pins as follows:






The large diameter - arrow 1 - faces the engine.

The small diameter - arrow 2 - faces the adapter.

- Counter hold the crankshaft and loosen the drive plate bolts using (T40058) and a wrench.






Turn the crankshaft only in direction of - arrow -.

- Remove the 6 bolts - arrow - from the clutch module. Turn the crankshaft an additional 60° in the direction of engine rotation.






- Remove the bolt - arrow - from the ATF pipes.






Ignore - 1 and 2 -.

Vehicles with Version 1 ATF Pipes






Place a cloth underneath to soak up any escaping ATF.

- Remove the bolts - arrows - and then remove the ATF line - 1 - from the transmission.

Ignore - 2 and 3 -.

- Remove the bolt - 1 -.






- Remove the circlip - arrow - and then remove the ATF line from the ATF filter.

Ignore - 2 -.

- Secure the ATF lines - 1 and 2 - upward.






Ignore - 3 -.

- Seal any open lines and connections with a clean plug from the (VAS 6122).

Vehicles with Version 2 ATF Pipes






Place a cloth underneath to soak up any escaping ATF.

- Remove the bolts - arrows -, remove the ATF pipes - 1 and 2 - from the ATF filter housing and tie them up.

- Seal any open lines and connections with a clean plug from the (VAS 6122).

- Remove the bolt - arrow - and move the coolant recirculation pump (V50) to the side.






All Vehicles






- Equip the (VAS 6131 A) with the (VAS 6131/10) , (VAS 6131/13-7) and (VAS 6131/14) as follows:

The other attachments remain unchanged.






- Install the (VAS 6131/13-7) at the right front of the engine in the threaded hole as shown in the illustration.






- Install the (VAS 6131/13-7) on the scissor lift table and tighten it to 20 Nm.

- Attach the mounting elements from the (VAS 6131/10) and (VAS 6131/14) at the front of the transmission as shown in the illustration.






- Rotate the left and right spindles up until the (VAS 6131/14) rests firmly against the transmission.

- Attach mounting element base plates to the (VAS 6131 A) and tighten to 20 Nm.

- Remove the starter bolts - 1 and 2 -.






- Press the starter off the transmission and leave it in the installation position.

- Remove the remaining bolts - 3 through 10 - that attach the engine to the transmission.

Ignore - A -.

- Loosen clamping bolts - 1 - on sides of (VAS 6131 A) and pull rear table plate with transmission toward rear - arrow -.






Engine, Installing

Special tools, testers and auxiliary items required

Ring Spanner Insert AF 16 (V.A.G 1332/14)

Assembly Aid (T40169)

Transportation Lock (T40170)

Scissor-Type Assembly Platform (VAS 6131 A)

Tightening Specifications

The tightening specifications apply only to lightly greased, oiled, phosphated or blackened nuts and bolts.

Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not.

Do not use any parts that have had the lubrication removed.

Tightening specification tolerance +/- 15%.






Subframe mount, refer to => [ Subframe Mount Overview ] Subframe Mount Overview.

Ground Bolt to Strut Tower - Tightening Specification





- Tighten the ground bolt - 1 - to 9 Nm.

Tightening Specification for Ground Wires to the Longitudinal Member





- Tighten the nut - arrow - to 9 Nm.

Engine to S-Tronic Transmission 0B5











The aluminum bolts - 2 through 10 - may be used two times. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be used the first time - arrow -.






To prevent damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt using a 14 mm socket with a 1/2 drive, which is inserted in to the vise, as illustrated.

Do not used bolts marked with an "X" again.

Procedure

Replace the bolts which are being tightened with an additional turn.

Replace self-locking nuts and bolts and seals, gaskets and O-rings.

In vehicles with S-Tronic transmission 0B5, there is a needle bearing in the drive plate. Check if the needle bearing is inserted before installing. Needle bearing, removing from and installing on drive plate. Refer to => [ Needle Bearing on Drive Plate ] Service and Repair.

The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.

Secure all hose connections with hose clamps of the same type as those equipped by the factory. Refer to the Parts Catalog.

To mount the air guide hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.

When installing, bring all cable ties back to same positions.

- Install the engine supports and engine mount. Refer to => [ Subframe Mount Overview ] Subframe Mount Overview.

- When joining the engine and subframe, hold the ATF lines in their installation position.

- Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.

- The following preparations must be made before connecting the engine and transmission:






- Insert the (T40169) into the transmission housing and clutch module from underneath as illustrated.

The assembly aid must engage in the semicircular opening - 1 - and in the inspection hole - 2 -.

The inspection hole is only in one location on the circumference so rotate the clutch module as needed.

- Install the assembly aid bolt into the hole on the transmission housing.

- Install the (T40170) into the transmission housing and the clutch module from underneath and secure it to the flange shaft - 1 -.






- Check if the alignment sleeves - A - for centering the engine/transmission are in the cylinder block and insert them if they are not.






- Inspect the aluminum bolts used to connect the engine to the transmission to see if they can be used again and mark them, if necessary.

- Attach the transmission to the engine and the tighten the bolts - 1 and 6 through 10 -.

- Remove the (T40170) and (T40169).

The following procedure is necessary to assure that the clutch module contacts the drive plate evenly and does not get bent.






- Press the clutch module - 2 - slightly against the drive plate - 3 - using a pry bar - 1 - in - arrow -.

- Secure the clutch module to the drive plate as follows:






Tighten the bolt with the (V.A.G 1332/14).

- Install the first bolt - arrow - and tighten by hand (2 Nm).

- Insert the (T40058) guide pins as follows:






The large diameter - arrow 1 - faces the engine.

The small diameter - arrow 2 - faces the adapter.

- Rotate the crankshaft 180° further in direction of engine rotation - arrow - using the (T40058) and ring wrench.






- Tighten the bolts that are accessible in this position to the tightening specifications.

- Turn the crankshaft 60° further and tighten the remaining 5 bolts to the tightening specification.

- Install the power steering hydraulic oil lines.

- Install the coolant recirculation pump.

- Install ATF lines.

- Install the left and right drive axles on the transmission flange shafts.

- Install the catalytic converters: for the left one, refer to => [ Left Catalytic Converter ] Left Catalytic Converter and for the right one, refer to => [ Right Catalytic Converter ] Right Catalytic Converter.

- Next, raise engine/transmission subassembly high enough using (VAS 6131 A) until dimension - a - is reached between subframe and body.






- a - = minimum 100 mm

- Install the selector lever cable and adjust if necessary.

- Continue raising the engine/transmission subassembly using the (VAS 6131 A).

- Align the subframe and transmission carrier using the marks made on the longitudinal members during removal.

- Tighten the subframe bolts only to the tightening specifications, do not tighten them further (tighten the bolts only after axle alignment).






Risk of accident due to loose connections.

If the bolts in the subframe are not tightened to final torque, vehicle must not be driven.

- Tighten the tunnel crossmember bolts - arrow -.






Install in reverse order of removal paying attention to the following:

- Attach the steering intermediate shaft to the steering gear.

- Install the driveshaft.

- Install the front muffler. Refer to => [ Front Muffler ] Front Muffler.

- Install exhaust system free of stress. refer to => [ Exhaust System, Installing ] Removal and Replacement.

- Install the front crossmember.

- Install the subframe, cross brace, the upper control arm and stabilizer bar and tighten the suspension strut on the left and right control arms.

- Install diagonal braces.

- Install brake caliper.

- Install Engine Control Module (ECM).

- Electrical connectors and wiring routing.

- Install the wires, terminal 30, wire junction 2 (TV22) and the engine compartment E-box cover. Refer to => [ Ground Bolt to Strut Tower - Tightening Specification ] , => [ Tightening Specification for Ground Wires to the Longitudinal Member ].

- Install the tower brace.

- Install the windshield wiper fluid reservoir filler tube.

- Install refrigerant lines.

- Be sure to follow the procedure for connecting the battery and afterwards.

There is a risk of destroying control modules with excess voltage.

Do not use a charger as a starting aid.

- Install the fuel supply hose and air filter housing.

- Install the lock carrier braces.

- Fill the engine oil and check the level.

- Before starting the engine for the first time, check the fluid level in power steering reservoir.

The power steering pump must not run dry.

- Connect the coolant hose to the coupling. Refer to => [ Connect the Coolant Hose to the Coupling ] Radiator and Coolant Fan Overview.






- Fill with coolant => [ Filling ] Service and Repair.

Do not use drained coolant in the following situations:

If the cylinder head or cylinder block was replaced.

If the coolant is contaminated.

- Fill the refrigerant circuit.

- Install the wheel housing liners.

- Install the front wheels.

- Perform axle alignment.

Risk of accident due to loose connections.

Tighten the subframe bolts to the specification after performing axle alignment.

- Fill with ATF.

- Install the noise insulation.