Withdrawal
Carefully! Danger of contamination from leaking hydraulic oil. Since the hydraulic pump starts even when the ignition is switched off, it is necessary to disconnect the battery. There is a risk of damage to electronic parts when disconnecting the battery. Carefully follow the process of removing the battery.
Disconnect ground cable from battery. Wash the outside of the hood and cover it with a protective cover. Unlock the service cover from the inside. Unlock the bonnet cover and pull it slightly forward. Pull on protective boot -VAS 6011- on bonnet. Do not place the hood cover on the edges. Remove bonnet and place on protective cover -VAS 6011-. Unscrew vacuum reservoir approx. 1/2 turn. The hydraulic oil level in the reservoir increases.
Unscrew bolt -1- on top of heat shield -2- of gearbox.
Use a screwdriver to remove the clamp of the pipe-hose lines from the gearshift unit. Remove pipes and hoses -1- and -2- from gearbox. Seal open pipes and fittings with clean plugs from engine plug set -VAS 6122-. Unplug electrical connector -3- for speed sender -G68-.
Mark connectors for valves -2- and -4- arrows -A, B- for refitting. Unplug electrical connectors from valves -1...4-.
Remove soundproofing. Unscrew heat shield -arrows- for right drive shaft.
Remove bolts -3- and remove heat shield -2- of gear selector box.
Unplug electrical connectors -1- and -2- of gear detection potentiometers -G239-/-G240-. Detach wiring harness from retainers on gear selector box -arrows- and move wires clear.
Loosen bolt -1- and remove gearshift pin -A-. Remove bolts -2- and -3-. Remove selector box from gearbox -B- and carefully pull downwards.
Installation
Install in reverse order, paying attention to the following: Loosen transit bolt -arrow-.
Clean threaded hole in gearshift pin -A- with a tap to remove any remaining thread varnish. The gearbox must be in neutral. Tighten the gearshift block bolts. Attach the wiring harness to the gearshift unit. Connect connectors -1- and -2- of gear detection potentiometers -G239-/-G240-, taking into account the different cable lengths. Long wire for potentiometer 1 for gear detection. -G239-. Short wire for gear detection potentiometer 2 -G240-. Check wiring and plug connections according to wiring diagram. Install soundproofing.
Connect connectors according to markings made before removal -arrows A, B-.
- 1. Connector for gear selection valve 1 -N284-
- 2. Connector for gear selection valve 2 -N285-
- 3. Connector for gear selection valve 3 -N286-
- 4. Connector for gear selection valve 4 -N287-
Check wiring and plug connections according to wiring diagram.
Carefully! Gearbox damage. Make sure that the pipes and hose lines are installed in accordance with the color markings. If the pipe-hose lines are installed incorrectly, the gearshift unit may fail when the AHE is connected.
Plug in electrical connector for speed sender -G68-. Tighten receiver. Pay attention to battery installation work. Turn on the ignition (the hydraulic fluid level in the expansion tank decreases). Perform a visual inspection of the hydraulic system and check for leaks. Check the oil level in the reservoir of the clutch drive and the gear shift mechanism; add oil if necessary. Adjust gear selector.
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