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.