Removal and Replacement
Transmission Removal and Installation
Special Tools and Workshop Equipment Required:
- Engine Support Bridge -10-222A-
- Bracket for Engine -10-222A/1-
- Additional Hooks (2) -10-222A/2-
- Engine Support Adapter -10-222A/3-
- Hose Clamps Up to 25 mm Dia. -3094-
- Transmission Support -3282-
- Adjusting Plate -3282/27-
- Transmission Support Jig -3336-
- Torque Wrench (5-50 Nm) -V.A.G 1331-
- Torque Wrench (40-200 Nm) -V.A.G 1332-
- Engine/ Transmission Jack -V.A.G 1383/A- with Universal Support -1359/2-
- Step Ladder -VAS 5085-
- Adapter -3282/52-
- Spring Type Clip Pliers -VAS 5024-
Removing
- First check whether a coded radio is installed. If so, obtain the anti-theft code.
- Remove the cover from the engine.
- Remove the connecting hose -1- for the crankcase ventilation (if equipped) from the cylinder head cover.
- Remove the Evaporative Emission (EVAP) canister hose -2-.
- Remove the coolant line bracket from the plenum chamber -arrows-.
- Remove the intake hose -1-, the connector -2- and the hose -3- from the Mass Airflow (MAF) sensor.
- Remove the bolts -4 and 5- and then remove the air filter housing.
- Remove the intake hose -1-.
- Disconnect the connector -arrow- from the speedometer vehicle speed sensor.
- Pull the safety mechanism on the shift cable (selector cable) all the way forward in the -direction of arrow 1- and then to the left in the -direction of arrow 2 and then lock it.
- Remove the support bolts -arrows- from the transmission.
- Tie up the shift cable and the selector cable.
- Remove the power steering line clamp nut -arrow 1-.
- Remove the lock washer -arrow 2- from the relay lever -A- and then the relay lever.
- Remove the nut -arrow 3- and remove the transmission shift lever -B-.
Use the -20-10- if necessary.
- Remove the nut -arrow- and remove the ground cable from the upper engine/ transmission bolt.
- Disconnect the wire -arrow 1- from the starter.
- Disconnect the connector from the backup lamps -arrow 2-.
- Remove the cable bracket -A- from the starter -arrow 3-.
- Remove the upper bolt for the starter.
- Clamp off the hose to the clutch slave cylinder using the -3094-.
- Remove the clamp -arrow- and the hose/line assembly in the -direction of arrow-.
NOTE:
Do not press the clutch pedal.
- Remove the upper engine/ transmission bolts.
- Disconnect any hoses and cables in the area of the lifting eyes on the engine.
- Install the -10-222A- with the -10-222A/1-, -10-222A/2- and the -10-222A/3-.
- Preload the engine/ transmission subassembly slightly using the spindles.
- Remove the right wheel.
- Turn the steering wheel to the left.
- Lift the vehicle.
- Remove the noise insulation.
- Remove the radiator and fans.
- Remove the left noise insulation fasteners -arrows- and noise insulation.
- Remove the right noise insulation.
- Remove the right drive axle head shield.
- Remove the drive axles from the flange shafts and tie them up as high as possible. Be careful not to damage the surface protection.
- Separate the exhaust system, remove the dual catalytic converter and remove the front exhaust pipe from the exhaust manifold.
- Remove the power steering line from the starter and from the transmission.
- Remove the starter.
- Remove the bevel box transmission support bolts -arrows- from the engine and the bevel box.
- Remove the bolt -arrow- above the bevel box.
- Remove the rear engine/transmission bolt.
- Remove the pendulum support bolts -arrows A and B-.
- Mark the position of driveshaft with flexible disc to the bevel box flange.
- Remove the driveshaft flexible disc bolts -arrows- from the bevel box flange.
- Position the -V.A.G 1383/A- with the -V.A.G 1359/2- under the transmission and then lift the transmission until it is parallel with the transmission mount.
- Remove the power steering fluid reservoir from the engine mount but do not loosen the hoses.
- Remove the engine mount to engine mount bracket bolts -arrows- from the top.
NOTE:
Use a -VAS 5085- to loosen bolts.
- Remove the transmission mount -2- to transmission mount bracket -1- bolts -arrows-.
NOTE:
Use -VAS 5085- to loosen the bolts.
- Remove the -V.A.G 1383/A- and -V.A.G 1359/2- from under the transmission.
- Push the engine/ transmission carefully forward so the the pin on the driveshaft flange is free.
- Carefully move the transmission into an angled position. Rotate the spindle on the -10 - 222 A- down approximately 60 mm.
- Remove the transmission mount bracket -1- bolts -arrows- from the transmission.
- Lower the engine/ transmission approximately 25 cm to dimension -a- by turning the left and right spindles -arrows- on the -10/222A-.
- Measure dimension -a- between the bottom of the transmission mount -1- and the bolting surface of the transmission mount bracket on the transmission -2-.
- Be careful of the wiring harness when lowering the engine/ transmission.
- Remove the lower engine/ transmission bolts.
To remove the transmission, the -3282- must be equipped the -3282/27-.
- Align the arms on the transmission support so that they match up with the holes in the adjusting plate.
- Install the support elements -A- as illustrated on the adjusting plate.
- Move the -V.A.G 1383 A- under the vehicle. The arrow symbol -B- on the adjusting plate must point in the direction of travel.
- Align the adjusting plate so that it is parallel to the transmission.
- Secure the transmission to the -3282- using the bolt -A-.
- Remove the bracket bolts -arrows- for the secondary air pump -1- from the engine.
- Remove the engine/ transmission bolt -arrow A-.
- Be careful of the lower intermediate plate on the engine.
- Remove the transmission from the alignment sleeves.
- Turn the spindles on the -3282- and rotate the transmission -1- upward near the bevel box -3-
- Guide the transmission carefully away from the flywheel (starter ring gear) and push it toward the subframe.
- Turn the spindles on the -3282- to the left and lower the transmission so that it is at an angle.
- Guide the bevel box past the attaching eye -arrow A- and the past the oil pan -2-, as illustrated -arrow B-.
- At the same time, carefully push the engine forward with a second technician.
NOTE:
When moving the engine/ transmission subassembly, pay attention to the connection lines and hoses.
- Lower the transmission. Pay attention to the subframe when doing this -arrow-.
- Use the spindles on the -3282- to adjust the position of the transmission while lowering it.
NOTE:
Pay attention to the power steering lines when lowering the transmission.
Installing
- Clean all the threaded holes with a thread tap to remove any locking fluid residue.
- Always replace the self locking nuts and bolts.
- Clean the splines on the input shaft and then lightly lubricate them with grease -G 000 100-.
It must be possible to slide the clutch plate back and forth on the input shaft.
- Make sure the alignment sleeves for centering the engine/ transmission are installed inside the cylinder block. Install them if necessary.
If the alignment sleeves are missing, it will be difficult to shift, there will be clutch problems and transmission may make noises (loose rattling).
- Make sure the intermediate plate fits correctly on the engine.
To install the transmission, the -3282- must be equipped the -3282/27-.
- Align the arms on the transmission support so that they match up with the holes in the adjusting plate.
- Install the support elements -A- as illustrated on the adjusting plate.
- Place the transmission on the -V.A.G 1383 A-.
- Align the adjusting plate so that it is parallel to the transmission.
- Secure the transmission to the -3282- using the bolts -A-.
- Move the -V.A.G 1383 A- under the vehicle. The arrow symbol -B- on the adjusting plate must point in the direction of travel.
- Turn the spindles on the -VAS 3282- and raise the transmission at an angle on the left side near the bevel box.
- Lift the transmission carefully and guide it past the subframe -arrows-.
- Carefully push the engine forward with a second technician.
NOTE:
Be careful of the connection lines and hoses when moving the engine.
- Guide the bevel box past the attaching eye -arrow A-and the past the oil pan -2-, as illustrated -arrow B-.
- Rotate the transmission -1- downward near the bevel box by turning the spindles on the -3282- and guide it into the flywheel (starter ring gear).
- Line up the transmission and the engine and install it.
- Install the engine/ transmission bolt -arrow A- and tighten it to specification.
- Position the bracket for the secondary air pump -1- to the engine and install the bolts -arrows-.
- Install the lower intermediate plate.
- Install the lower engine/ transmission bolts and tighten them to specifications.
- Lift the engine with the transmission carefully. To do this, turn the spindles on the -V.A.G 10-222A-
- Install the transmission mount bracket -1- with the new bolts -arrows- and tighten them to specifications.
- Position the -V.A.G 1383/A- with the -V.A.G 1359/2- under the transmission and then lift the transmission until it is parallel with the transmission mount.
- Align the engine/ transmission into its installed position.
- Install new bolts -arrows- for the transmission mount -2- to transmission mount bracket -1- and tighten them to specifications.
NOTE:
Use a -VAS 5085- to install the bolts.
- Install new bolts -arrow- for the engine mount to engine mount bracket.
NOTE:
Use a -VAS 5085- to install the bolts.
WARNING!
Remove the -10/222A- only after the bolts for the engine and transmission mounts have been tightened to specifications.
NOTE:
Install the engine/ transmission mount free of tension.
- Attach the power steering fluid reservoir to the engine mount.
- Install the bolt -arrow- above the bevel box and tighten it to specification.
- Position the support to the bevel box and transmission and install the bolts -arrows-.
- Press engine/ transmission assembly to the bulkhead; while doing so, carefully guide the bevel box pin into flange/ driveshaft.
NOTE:
- The seal in the driveshaft flange must not be damaged when removing and installing transmission.
- Replace the driveshaft if it is damaged.
- Slip the driveshaft horizontally onto the respective guide pin.
- Attach the driveshaft and flexible disc to the bevel box flange shaft. Install the bolts -arrows- and tighten them to specification, see -item 4-.
- Attach the front exhaust pipe to the exhaust manifold.
- Install the pendulum support and bolts -arrows A and B-.
- Install with new bolts.
- Attach the drive axles to the transmission.
- Install the right drive axle heat shield.
- Install the radiator and fans.
- Install the dual catalytic converter and then assemble the exhaust system.
- Position the starter and install the lower bolt.
- Install the bracket for the power steering line to the starter and to the transmission.
- Insert the upper engine/ transmission bolts and tighten them to specification.
- Attach the ground cable to the upper engine/ transmission bolt and install the nut -arrow-.
- Connect the connector -arrow- to the speedometer vehicle speed sensor.
- Install the hose/line assembly in the -direction of the arrow- and push the clamp -arrow- down.
- Remove the -3094-.
- Install the upper bolt for the starter.
- Attach the cable bracket -A- to the starter -arrow 3-.
- Connect the connectors for the starter -arrow 1- and to the backup lamp -arrow 2-.
- Install the transmission shift lever -B- -arrow 3-.
- Tighten the nut -arrow 3- to specification.
- Install the relay lever -A- and secure it with a lock washer -arrow 2-.
- Install the power steering line -arrow 1-.
- Attach the cable mounting bracket to the transmission and tighten the bolts -arrows0 to specification, see -item 6-. Push the hose line onto the cable mounting bracket, if necessary.
- Install the battery tray.
- Install the complete air filter housing and tighten the bolts -4 and 5-.
- Install the intake hose -1-.
- Connect the intake hose -1-, the connector -2- and the hose -3- to the Mass Airflow (MAF) sensor.
- Install the battery.
- Attach the crankcase ventilation hose -1- to the cylinder head cover.
- Attach the Evaporative Emission (EVAP) canister hose -2-.
- Push the coolant line bracket onto the pins under the plenum chamber -arrows-.
- Connect the negative cable to the battery.
NOTE:
Note the radio code on vehicles with a coded radio.
- Check the transmission fluid level in the manual transmission and bevel box.
- Bleed the clutch system.
- Adjusting the shift unit.
- Install the noise insulation.
- Install the engine cover.
Tightening Specifications:
