Withdrawal
1. Disconnect the negative cable (-) battery.
Warning: Follow the instructions in Section Replacing the battery.
2. Remove engine covers, refer to Section Removal and installation of the upper engine cover / lower protection of the engine compartment / subframe.
3. Turn out nuts of fastening of a turbocharger.
4. Turn out all connecting bolts the engine/transmission which are accessible from above.
5. Install the yoke and sling the engine.
Caution: The fuel supply line is under pressure! Before opening the hose connection, cover it with a thick cloth. Then relieve the pressure by carefully disconnecting the hose.
6. Raise and place the vehicle on stands.
7. Models with parking heater: Remove the bolts securing the parking/auxiliary heating outlet pipe to the bottom cover of the engine compartment.
8. Turn away bolts of fastening and remove the holder of the bottom cover of an impellent compartment (arrow).
9. Remove the heat shield over the right drive shaft.
10. Turn away bolts of fastening and remove the left and right covers (arrows) exhaust pipe.
11. Remove the front cross member of the tunnel (1) (arrows on the accompanying illustration).
12. Remove downpipe (3) from terminal sleeve (2), refer to Part Systems of release and decrease in toxicity of the fulfilled gases. Turbocharger.
13. Remove heat shield (4) over the exhaust system.
14. Turn out the bottom connecting bolts the engine/gearbox (arrows on the accompanying illustration).
15. Disconnect both drive shafts along the flanges and tie them on the wire, refer to Section Removal and installation of a power shaft.
Warning: Be careful not to damage the protective coating of the drive shafts when unscrewing.
16. Remove the starter, but do not disconnect the cable from the starter. Attach the starter to the wire to the body.
17. At the service station, the gearbox is fixed and supported by a VAG lift. If the specified lift is not available, move a garage lift with a wide wooden gasket under the gearbox and slightly raise the gearbox.
18. Remove the bolts first (2) and then bolts (3) across the tunnel. Remove both nuts (4), remove the tunnel cross member.
19. Carefully lower the engine/gearbox jack until the gearbox is visible. Remove the lift.
20. Remove the bolt (A) fastening the rod to the gearbox and disconnect the shift pivot from the axle.
21. Disconnect the push rod by unscrewing the hexagon socket screw (IN) at the checkpoint.
22. Remove the connector (1), if present, from the holder (arrow on accompanying illustration). Disconnect the connector and move the cable aside.
23. Disconnect the connector (A) tachometer sensor and (IN) reversing lamp on the left at the checkpoint.
24. Disconnect the engine speed sensor, if any, on the left of the gearbox (arrow on accompanying illustration) and take him aside.
25. Turn out the bottom connecting bolts the engine/gearbox, but not bolts (A) And (IN).
26. Move a suitable lift under the gearbox and fix the gearbox with an adjusting plate.
27. Turn out the remained connecting bolts the engine/gearbox (A) And (IN).
28. Press the gearbox away from the engine and slowly lower it down.
Installation
Caution: When replacing any parts or bolts installed on the gearbox, be aware of the following: The gearbox housing is made of magnesium or aluminum alloy. In accordance with this, certain parts to be installed, such as a cover, and bolts, are used. If aluminum transmission parts are mounted on a magnesium alloy housing, the latter will be subject to corrosion. This also applies to the engine/gearbox flange mounting bolts. They have a special coating for the magnesium alloy gearbox housing. A sign of a gearbox made of magnesium alloy is the inscription «Mg AL 9 Zn 1» on the underside of the gearbox and in the area of \u200b\u200bthe oil filler plug.
1. Before installation, check the clutch, refer to Section Removal, installation and clutch check.
2. Clean input shaft spline and lightly lubricate with MoS 2 AUDI-G000100.
Caution: The clutch disc must slide easily onto the gearbox input shaft. Remove excess lubricant.
3. Clean all threaded holes into which self-locking bolts are screwed with a tap from sealant residue. Be sure to replace self-locking bolts and nuts with new ones.
4. Check the wear of the clutch release bearing, replace if necessary. If the plastic bearing has grooves deeper than 0.5 mm, the bearing must be replaced.
5. Lubricate the adjacent surface of the pusher at the clutch release bearing lever with copper grease, for example, «Z381 351 TE».
6. Check if the centering sleeves are in place to center the engine/gearbox connection in the cylinder block, insert if necessary.
7. Watch the correct position of an intermediate plate at the engine if that is available.
8. Enter the gearbox horizontally into the clutch. If during installation the input shaft of the gearbox does not enter the driven disk, turn the shaft by the flange by hand.
9. Install the clutch slave cylinder with holder. Using a pry bar, insert the cylinder so that the mounting bolt can be easily inserted. Torque tighten the bolt25Nm.
10. Install the starter, refer to Section Removal and installation of a starter.
11. Screw in the bottom bolts (A) for mounting the engine with gearbox and (IN) for mounting the starter.
12. Lower the engine/gearbox assembly.
13. Tighten the upper engine/gearbox mounting bolts to the specified torque.
14. Attach the tunnel cross member to the gearbox support (1).
15. Attach the tunnel cross member to the body. Screw in the bolt first (2) then bolt (3).
16. Tighten the bottom 3 bolts securing the engine to the gearbox to 45 Nm.
17. Reinstall the shift rod. Fasten it with a torque of 20Nm.
18. Install the push rod and secure it with a torque of 40Nm.
19. Install the drive shafts and shaft shield, refer to Section Removal and installation of a power shaft.
20. Connect all previously disconnected connectors.
21. When laying electrical connections, make sure that all clamps removed or cut during dismantling are installed in their original places.
22. Install the exhaust pipe heat shield. Install the downpipe and install the exhaust system, refer to Section Removal and installation of the exhaust system. Replacement of the central, additional muffler, end pipe.
23. Check up adjustment of a drive of a gear change, address to the Section Adjustment of a drive of a gear change.
24. Check the oil level in the gearbox, refer to Section Checking the oil level in a manual transmission.
25. Attach the negative (-) battery cable.
Warning: Follow the instructions in Section Replacing the battery.
Tightening torques for threaded connections
Engine/gearbox mounting bolts. Engines 1.6, 1.8, 1.9, 2.0 l
Position |
Bolt |
Moment tightening |
Engines 1.6, 2.0 l |
||
1, 3, 4 |
M12 x 75 |
65Nm |
2 |
M12 x 90 |
65Nm |
5, 11 |
M12 x 110 |
65Nm |
7-10 |
M10 x 45 |
45Nm |
11 | M12 x 130 | 65Nm |
A |
Centering bushes | |
Engines 1.8, 1.9 l: |
||
1, 3, 4 | M12 x 67 | 65Nm |
2, 6 | M12 x 90 | 65Nm |
5, 11 | M12 x 110 | 65Nm |
7-11 | M10 x 45 | 45Nm |
A |
Centering bushes |
Engine/gearbox mounting bolts. Engines 2.4, 3.0 l
Position |
Bolt |
Tightening torque |
Engine 2.4 l |
||
1, 9, 10, 11 |
M10 x 45 |
45Nm |
2 |
M10 x 135 |
65Nm |
3 |
M12 x 130 |
65Nm |
4, 5, 6 |
M12 x 67 |
65Nm |
7 | M12 x 90 | 65Nm |
8 | M12 x 80 | 65Nm |
A | Centering bushes | |
Engine 3.0 l | ||
1, 9, 10, 11 | M10 x 60 | 45Nm |
2 | M10 x 150 | 65Nm |
3 | M12 x 130 | 65Nm |
4 | M12 x 80 | 65Nm |
5, 6, 8 | M12 x 90 | 65Nm |
7 | M10 x 100 | 45Nm |
A | Centering bushes |
Bolts of fastening the support of the engine/stabilizer
- 1 - Stabilizer (2) to engine support console 25 Nm
- 3 - Engine support to engine support console 25 Nm
Caution: Nuts (1) are sure to be replaced.
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