Audi Workshop Service and Repair Manuals

Removing and installing gear actuator Special tools and workshop equipment required

t  Protective cover for bonnet Audi A2 -VAS 6011-

t  Engine bung set -VAS 6122- Removing   Caution There is a risk of contamination from escaping hydraulic fluid. The battery must be disconnected as the hydraulic pump starts up even with the ignition switched off. When disconnecting the battery there is a risk of serious damage to electronic components: Observe the correct procedure for disconnecting the battery. –  Disconnect the earth wire at the battery → Rep. gr.27.

–  Wash outside of bonnet and dry with a chamois leather. –  Release service flap from inside. –  Release bonnet -arrows- and pull it forwards slightly.

–  Fit the protective cover -VAS 6011- over the bonnet.   Note

Do not store the bonnet in an upright position. –  Detach the bonnet and set it down on the protective cover -VAS 6011-.

–  Unfasten the pressure accumulator by roughly 1/2 a turn. l  The hydraulic fluid level in the reservoir increases.

–  Remove the bolt -1- at the top of the gear actuator heat shield -2-.

–  Use a screwdriver to prise the hose/pipe assembly clip out of the gear actuator. –  Pull the hose/pipe assembly -1- and -2- out of the gear actuator. –  Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-. –  Unplug the connector -3- at the vehicle speed sender -G68-.

–  For re-installation, mark -arrows A, B- the connectors for the valves -2- and -4-. –  Unplug electrical connectors at valves -1 … 4-.

–  Remove the noise insulation -arrows-.

–  Unscrew the right drive shaft heat shield -arrow-.

–  Remove the bolts -3- and detach the gear actuator heat shield -2-.

–  Unplug the connectors -1- and -2- at the gear detector potentiometers -G239-/-G240-. –  Disengage -arrows- wiring harness from fasteners at gear actuator and move clear.

–  Slacken off the bolt -1- and detach the selector finger -A-. –  Remove bolts -2- and -3-. –  Detach the gear actuator from the gearbox -B- and carefully take out downwards.

Installing l  Tightening torque → Fig., → Fig.. Installation is carried out in reverse sequence; note the following: –  Remove the transportation safeguard bolt -arrow-.

–  Use a tap to remove remnants of locking compound from the tapped hole in the selector finger -A-. l  The gearbox must be in neutral. –  Tighten the gear actuator bolts → Fig..

–  Attach the wiring harness to the gear actuator -arrows-. –  Plug in the connectors -1- and -2- at the gear detector potentiometers -G239-/-G240-, paying attention to the different wire lengths. t  Long wire for gear detector potentiometer 1 -G239-. t  Short wire for gear detector potentiometer 2 -G240-. –  Use the current flow diagram to check wiring and connectors → Current flow diagrams, Electrical fault finding and Fitting locations. –  Install noise insulation → Rep. gr.50.

–  Fit the connectors in line with the marks -arrows A, B- made on removal. 1 -  Connector for selector lever valve 1 -N284- 2 -  Connector for selector lever valve 2 -N285- 3 -  Connector for selector lever valve 3 -N286- 4 -  Connector for selector lever valve 4 -N287- –  Use the current flow diagram to check wiring and connectors → Current flow diagrams, Electrical fault finding and Fitting locations.

Caution There is a risk of damage to the gear actuator. t  Make sure the hose/pipe assemblies are fitted in accordance with the coloured marks → Fig.. t  If the hose/pipe assemblies have been incorrectly inserted, there is a risk of irreparable damage to the gear actuator on connecting the battery. –  Plug in the connector at the vehicle speed sender -G68-. –  Secure the pressure accumulator → Chapter. –  Observe correct procedure after connecting battery → Rep. gr.27. –  Switch on ignition (hydraulic fluid level in reservoir falls). –  Perform a visual check for leaks in the hydraulic system. –  Check the fluid level in the reservoir for the clutch mechanism and selector mechanism and replenish the fluid → Booklet809. –  Adjust the gear actuator → Chapter.