Table of contents: Removal ↓ Installation ↓ Tightening torques when installing… ↓ Tightening torques ↓
Removal
Caution! Risk of damage to electronic components when disconnecting the battery. Carefully monitor the process of removing the battery.
Disconnect the battery ground cable. Wash the hood from the outside and cover it with a protective cover. Unlock the service cover from the inside. Unlock the hood cover "arrows" and pull it forward a little. Pull the protective cover "VAS 6011" onto the hood cover. Remove the hood cover and place it on the protective cover "VAS 6011". Using a screwdriver, unfasten the protective caps "3" and "4" of the windshield wiper arms. Unscrew the nuts of both windshield wiper arms a few turns. Alternately unfasten windshield wiper arms "1" and "2", tilting them slightly from the axis. Completely unscrew the nuts and remove the windshield wiper arms.
Disconnect the windshield washer line "3". If available, disconnect the plug connectors "4" and "5" of the heated windshield washer nozzles. Unfasten the hose clamp "6" using special pliers "V.A.G 1921" and remove the coolant drain line from the fairing grille. Remove the rubber seal "1" of the fairing grille. Remove the fairing grille "2". Release the windshield washer system line.
Unscrew the nuts and bolts "arrows". Remove the air duct in the forward direction and unscrew it to the right side of the car.
Remove the engine casing "arrows". Remove the noise-insulating pad installed underneath it, removing the engine crankcase ventilation hose for this. Remove the hydraulic control unit. Unscrew bolt "1" on top of the heat shield "2" of the gearshift unit.
Disconnect the "arrow" plug of the speed sensor "G68".
Disconnect the "arrow" connector of the gearbox speed sensor "G38".
Loosen the lock nut "B" and the adjusting nut on the clutch rod. Hang the clutch rod on the drive lever.
Instructions: It is prohibited to open the hydraulic line of the clutch slave cylinder.
Hang the wire bracket in the place marked with the "arrow" and remove the clutch slave cylinder from the stop "A". Put the clutch slave cylinder aside, do not open the system of lines. Unscrew the wire bracket of the gearbox mount. Unscrew all other brackets and lines of the gearbox.
Remove the front wheels. Remove the sound insulation. Unscrew the heat shield of the right drive shaft. Remove the left and right drive shafts.
Cut the wire retainer "2" and remove the cover "3" of the electromagnetic switch "1" in an upward direction.
Unscrew nut "2". Disconnect wires "3" of the electromagnetic switch of the starter. Unfasten the bracket of wires. Unscrew the upper bolt of the starter. Unscrew nut "1" and remove the lower ground wire of the starter. Disconnect the plug connector of terminal 50 "pos. 4" on the electromagnetic switch. Unscrew the lower double bolt, remove the starter downwards. Disconnect plug connector "5" of the reversing light switch "F4" and release
Unscrew the front catalytic converter "arrow" and fix it on the front wall of the body.
Unscrew bolts "3" and remove heat shield "2" of the gear shift unit.
Instructions: It is prohibited to open the hydraulic lines of the gear shifter.
Loosen bolt "1" a few turns. Remove gear shift pin "A" from the gear shift rod. Unscrew bolts "2" and "3". Secure the gear shifter as high as possible on the body.
Unscrew bolts "1, 3" and nut "2" and remove the lower support of the power unit.
Vehicles with power steering: remove hydraulic lines "1" and "2" from the steering gear.
Unscrew both upper engine-to-gearbox mounting bolts. Screw the rear left transport cover "T40016/1" to the cylinder head.
Install the adapter "10.222 A/3" on the crossmember "10.222 A". Install the crossmember "10.222 A" with the adapter "10.222 A/13" on the connecting edge of the wing. Fasten the adapters. "10.222 A/13" at the rear on the hood fastening hook "arrow".
Create a slight pre-tension of the power unit using the lead screws. Unscrew the "arrow" bolts of the left gearbox support. Carefully move the power unit to an inclined position by unscrewing the left lead screw of the crossmember "10.222 A" downwards.
Unscrew bolts "A" and remove gearbox console "B".
Equip the "3282" mount for removing the "085 DS" gearbox with the "3282/28" adjustment plate. Install the "3282" gearbox mount on the "VAG 1383 A" powertrain lift. Align the levers of the mounting device with the holes in the installation template. Screw on the "A" fastener as shown on the adjustment plate. Screw on the "3282/29" pins instead of the "C" fastener. Place the powertrain lift under the vehicle. Arrow "B" on the installation template shows the direction of movement.
The adjustment template "3282/28" should be oriented parallel to the gearbox.
Screw in the pin "3282/29" "arrows" into the holes for the bolts that secure the lower support of the power unit to the gearbox.
Unscrew the lower bolts "1" and "2" securing the engine to the gearbox. Press the gearbox away from the centering bushings and use the lead screws to set the mount for the "3282" gearbox to the tilt position to the left. Carefully lower the gearbox using the "VAG 1383 A" tilter. Change the position of the gearbox in the area of the subframe and the body on the left by lowering it using the lead screws for securing the gearbox.
Installation
Instructions. Replace bolts that have been tightened with additional turning. Replace self-locking nuts and bolts, as well as sealing rings, seals and sealing cuffs. Secure all hose connections with hose clamps of the corresponding series. When installing, install all binders in their places.
Tightening torques when installing gearboxes
Make sure that bushings "A" and "B" are installed in the cylinder block to align the engine and gearbox; if necessary, insert bushings. If there is a metal engine gasket, ensure that it is seated correctly. Clean the gear engagement of the input shaft and, if the clutch disc has been used, the gear connection of the hub, remove traces of corrosion and apply a very thin layer of consistent grease for the gear engagement of the clutch disc "G 000 100" to the gear engagement. Then move the clutch disc in one direction and the other until the hub moves easily on the shaft. Be sure to remove excess grease.
Carefully lift the gearbox using the universal grip "3282". Align the gearbox with the engine and install it.
First screw in and tighten the lower bolts "1" and "2" for fastening the engine to the gearbox, then the upper bolts. Install the gearbox console. Align the power unit relative to the installation position. To do this, tighten both running screws of the crossmember "10.222 A". Install the gearbox mount. Install the power unit support without tension. Disconnect the crossmember "10.222 A" only after tightening all the bolts of the gearbox console to torque. Remove the crossmember. Install the starter. Install the reversing light switch "F4". Vehicles with power steering: install the hydraulic lines. Install the drive shaft. Install the right drive shaft heat shield. Install the pendulum support. Install the front catalytic converter. Install the gear shifter.
Instructions. On a new gearbox, it is necessary to remove the "arrow" spring between the clutch release lever and the gearbox; otherwise the clutch slave cylinder will not function! The spring serves as a transport lock for the clutch release bearing.
Install the clutch slave cylinder bracket. Install the clutch slave cylinder. Check the gearbox oil level and add oil. Install sound insulation. Install the hydraulic control unit. Pay attention to the battery installation work.
Caution! Risk of damage to control units due to overvoltage. Do not use a charger as a starting aid!
Check the oil level in the clutch and gear shift reservoir; if necessary, add oil. Adjust the clutch. Perform basic adjustments in the "Car self-diagnosis" mode.
Tightening torques
Instructions. Tightening torques are valid only for lightly lubricated, oiled, phosphated or blued nuts and bolts. The use of additional lubricants such as engine or transmission oil is permitted, except for graphite-containing lubricants. Do not use degreased parts. Tightening torque tolerance is ±15%.
| M6 | 9 |
| M7 | 15 |
| M8 | 20 |
| M10 | 40 |
| M12 | 65 |
Heat shield for right drive shaft
Tighten the bolts of the heat shield "arrow" of the drive shaft to a torque of 23 Nm.
Gearbox console
Tighten bolts "A" of gearbox console "B" to a torque of 50 Nm and turn further by an angle of 90°.
Gearbox support
Tighten the gearbox support arrow bolts to a torque of 40 Nm and turn further by an angle of 90°.
Gearbox to engine
1) Tighten from the engine side.
2) Additionally secure the starter.
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