Remove noise insulation panels -1- and -2-. Remove left additional muffler.
Unscrew nut -1-hydraulic line of power steering. Risk of damage to chassis parts. If the power unit support, steering gear or subframe spacer is installed incorrectly, the vehicle must not be placed on wheels. Unscrew the bolts -arrows- and remove the subframe spacer.
Remove the right catalytic converter.
Unscrew bolts -arrow- for ATF lines.
Remove the stretch. Remove the end wall of the radiator tank.
To collect leaking ATF oil, place a rag under the disconnect point. Unscrew bolts -1- and -2-, remove the ATF lines from the gearbox and tie them on top. Seal open lines and pipes with clean plugs from the engine plug set -VAS 6122-.
Unscrew the bolts -2...5- accessible from above connecting the gearbox and engine. Install cross member -10 - 222 A- with connector -T40091/3- onto the shock absorber strut cups on the left and right, as shown in the figure. Secure the lead screw -10 - 222 A/11- to the right eye of the engine mount.
Install the other parts of the cross member -10222 A- as shown in the illustration. To do this, install the support -T40093/3- on the seam of the side member sheet. Secure the lead screw -10222 A/11 - to the left front eye of the engine mount.
Unscrew the bolts -arrows- and remove the heat insulation shield for the right drive shaft.
Unscrew the bolts -arrows- and remove the heat insulation shield for the left drive shaft. Unscrew the left and right drive shafts from the gearbox flange shafts.
Carefully! Risk of failure of the gearbox control unit (Mechatronik) due to static discharge. Do not touch the contacts in the gearbox plug with your hands.
To remove static charge, touch with your hand (without gloves) to the gearbox housing. Disconnect the gearbox connector by turning the rotary clip counterclockwise -arrow-. Release the wiring harness on the gearbox.
Disconnect electrical connector -2- from engine speed sender -G28- and free electrical connection. the wire. -Pos. 1- do not take into account.
Press the ball bearing -1- of the gearbox selector cable using lever -80-200- from the shift shaft lever. Remove the retaining bracket -2- and disconnect the automatic transmission selector cable from the gearbox. The selector cable must not be bent or broken.
Carefully! Risk of damage to the Airbag coil spring. Disconnect the universal joint from the steering gear only with the front wheels mounted straight. Do not change the position of the steering wheel or steering gear again; to do this, if necessary, secure the steering wheel with adhesive tape.
Remove bolt -arrow- from universal joint. Press the steering gear universal joint out and push it all the way up.
Unscrew the bolt, press the locking tab away from the gearbox and tilt it back -arrow-.
If present, remove bolts -arrows- and remove heat shield for propeller shaft.
Unscrew the bolt securing the propeller shaft to the gearbox, while holding it against turning using counterhold -T10172- using -T10172/5-. Move the cardan shaft to the rear main gear; constant velocity joints are movable in the axial direction. Tie the driveshaft to the side.
Remove trim -1- under gearbox -arrow-.
Insert the adapter guide pin -T40058- as follows: the large diameter -arrow 1- faces the engine, the small diameter -arrow 2- faces the adapter.
Hold the crankshaft to remove the torque converter bolts using the adapter -T40058-. During the final turn, turn the crankshaft only in the direction of engine rotation -arrow-.
Remove 6 bolts -arrow- for the torque converter; to do this, rotate the crankshaft 60°in the direction of engine rotation.
Remove starter bolt -1-. Remove the starter from the gearbox and leave it in its installation position. Remove the remaining bolts -6...11- of the engine/gearbox connection. Place engine and gearbox lift with gearbox mount -T40173- under gearbox and secure with tensioning belt -1- as shown in the illustration. For clarity, the gearbox mounting -T40173- is not shown in the figure. Unscrew the bolts -arrows- of the tunnel cross member.
First lower the gearbox using the engine and gearbox lift to dimension -a-. Dimension -a- = maximum 100 mm.
Lightly tighten both spindles -10 -222 A/11-. Press the gearbox away from the engine and carefully lower it using the tilt lever.
Installation of gearbox
Note: Replace bolts that are overtightened. Replace self-locking nuts and bolts and seals. rings, gaskets and seals. cuffs Secure all hose connections with hose clamps of the appropriate standard. When installing, install all cable ties in their original places.
Tightening torques when installing the gearbox
As a rule, before installing a replacement gearbox, blow out the ATF oil lines and ATF oil cooler with compressed air (Max. 10 bar). Before installation, be sure to clean the threaded holes in the cylinder block using a tap to remove any deposits. When installing a gearbox from an exchange stock: install the gearbox support, gearbox mount and tunnel cross member on the new gearbox. Place the gearbox on the gearbox mount -T40173- and secure with the tensioning belt -1- as shown in the illustration. Before connecting the engine and gearbox, carry out the following preparatory steps: turn the torque converter so that the hole next to the notch -arrow- is visible in the opening at the bottom of the gearbox housing, as shown in the figure. There is only one notch on the perimeter, so the torque converter should be rotated accordingly.
Place the transport protection -T40170- from below under the gearbox housing and attach it to the flange shaft -1-.
Check the presence of centering sleeves -A- for the engine and gearbox in the cylinder block, insert the sleeves if necessary. Check the aluminum bolts connecting the engine to the gearbox for reuse and mark if necessary. Place the gearbox on the engine and tighten bolts -1, 6...11-. Remove transport protection -T40170-. Loosen lead screws -10 - 222 A/11-. Raise the gearbox and tighten the bolts -arrows- of the tunnel cross member. Loosen the harness and remove the lift with gearbox mounting -T40173- from under the gearbox. The next stage of work is necessary to ensure uniform contact of the torque converter with the driven disk without distortion. Using the mounting lever -1-, lightly press the torque converter -2- away from the driven disc -3- in -direction of the arrow-.
Tighten the torque converter bolts on the driven disk as follows. To tighten the bolts, use ring spanner 16 -VAG 1332/14-. Screw in the first bolt -arrow- by hand (2 N'm).
Insert the adapter guide pin -T40058- as follows: the large diameter -arrow 1- faces the engine, the small diameter -arrow 2- faces the adapter.
Using adapter -T40058-, rotate crankshaft 180°in direction of engine rotation -arrow-.
In this position of the crankshaft, tighten the accessible bolt -arrow- to 60 Nm. Further rotate the crankshaft by 60°and tighten the remaining 5 bolts to a torque of 60 Nm. Tighten the remaining bolts -2...5-. Install in reverse order. Screw the universal joint to the steering gear.
Install the subframe spacer. Install the selector cable drive. Install ATF lines. Screw the left and right drive shafts to the shafts with the gearbox flange. Install the drive shaft heat shields.
Install the driveshaft. Install exhaust system and align without tension. Install soundproofing. Consider the measures required after connecting the battery. Check and adjust the selector cable. Check and adjust ATF oil level.
Tightening torques (Nm)
Bolts and nuts | |
M6 | 9 |
M7 | 15 |
M8 | 20 |
M10 | 40 |
M12 | 65 |
Thermal shield of the joint shaft - tightening torque
Tighten the bolts -arrows- of the heat insulation shield of the drive shaft to a torque of 23 Nm.
Attaching the gearbox to the engine
Pos. | Bolt | Nm |
1 | M10x50 (1) | 65 |
2.6 | М12Х100 (2) | 30 + 90° |
7 | М12Х125 (2) | 30 + 90° |
8,11 | M 10x60 (2) | 15 + 90° |
9 | M1 0x75 (2) | 15 + 90° |
10 | M1 0x95 (2) | 15 + 90° |
A | Centering sleeves |
- (1) Bolt strength 10.9. The steel bolt can be reused many times.
- (2) Aluminum bolts can be used twice.
Aluminum bolts -2...11- can be used twice. Therefore, after the first use, mark such bolts with two notches "X" -arrow-. To avoid damaging the bolts when making notches, do not clamp them in a vice. Insert the bolt as shown in the figure into the 14 socket with 1/2"-drive, which can then be secured in a vice. Tagged "X" Do not reuse bolts.
Tunnel cross member, gearbox cushion and gearbox support I 1. Nut: remove only if the gearbox mount must be disconnected from the gearbox support; 20 Nm; 2. Bolt: 70 Nm; 3. Bolt: 40 Nm; 4. Nut: 20 Nm; 5. Gearbox support; 6. Gearbox cushion; 7. Lower stop of the gearbox cushion; 8. Bolt: remove only if the gearbox mount must be disconnected from the gearbox support; replace; 20 Nm + 90°additional rotation; 9. Tunnel cross member
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