Audi Workshop Service and Repair Manuals

Removing gearbox on vehicles with 1.8 ltr. and 2.0 ltr. FSI turbocharged engine

Special tools and workshop equipment required

t	Adapter -VW 771/40-

t	Support bracket -10-222A-

t	Rack -10 - 222 A /1-

t	Hook -10 - 222 A /10-

t	Engine and gearbox jack -V.A.G 1383 A-

t	Stepladder -VAS 5085-

t	Gearbox support -3282-

t	Adjustment plate -3282/33-

t	Pin -3282/29-

t	Adjustment plate -3282/52-

t	Safety support -3282/59-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

Special tools and workshop equipment required

t  Hose clamps, up to Ø 25 mm -3094-

t  Engine support -3300 A-

t  Support -T10036- t  Bolt M6×20 (2x) t  Bolt M10×20 t  Grease -G 000 450 02- t  Grease for clutch plate splines -G 000 100-   Caution Follow steps required when disconnecting battery → Electrical system; Rep. Gr.27.

–  Release battery cover -arrow- and detach.

–  With ignition switched off, disconnect battery earth strap -arrow-.

Vehicles with air filter element in engine cover panel –  Remove engine cover panel with air duct -arrows- → Rep. Gr.24.

Vehicles with air cleaner housing in front of battery –  Remove complete air cleaner housing → Rep. Gr.24.

–  Remove engine cover panel -arrows-.

Continued for all vehicles –  Remove battery → Electrical system; Rep. Gr.27. –  Remove bolts -arrows- and detach battery tray -1-.

–  Detach securing clip -3- for gear selector cable from gearbox selector lever -1- and pull cable off pin -arrow-. Metal gate relay lever -2- –  Detach securing clip -4- for gate selector cable from gate relay lever -2- and pull cable off pin -arrow-.

Plastic gate relay lever l  To prevent damage to gate selector cable, cable end-piece must be detached from gate selector cable before removing relay lever. –  Pull locking mechanism forwards in direction of -arrow 1- onto stop and then turn to left in direction of -arrow 2- to lock. –  Then press gate relay lever forwards (in direction of -arrow 3-). –  Plastic gate relay lever is removed at a later stage together with cable end-piece.

Continued for all vehicles –  Detach cable support bracket from gearbox -arrows-; then move to one side and tie up together with selector cables.

–  Remove bolts -1- from engine/gearbox flange.

–  Remove the two top bolts on radiator cowl -top arrows-.

–  If there are hoses and cable connections in area of engine lifting eyes for support bracket -10-222A-, remove these now. Fit support bracket -10-222A- together with racks -10 - 222 A /1- and hook -10 - 222 A /11- onto wing mounting flanges. –  Partly take up weight of engine with spindle, but do not lift.

–  With vehicle still standing on its wheels, slacken off front left flange bolt -2- 90° (maximum). Do not slacken further, as this would damage the wheel bearing. –  Raise vehicle.

Audi A3 –  Release fasteners -1 and 2- and remove noise insulation (centre).

Audi A3 Cabriolet –  Remove noise insulation (centre) -1- → Rep. Gr.50.

–  Remove frame for noise insulation -arrow- → Rep. Gr.50. Continued for all vehicles

–  Remove wheel housing liner (front left) -fasteners 1 ... 3-.

–  Lift retaining clips -arrows- slightly and remove air hose.

–  Detach electrical connector -1-. –  Remove remaining bolts -bottom arrows- and take out radiator cowl from below.

–  Unplug electrical connector -2- for reversing light switch -F4-. –  Remove nut -1- and detach bracket from stud together with electrical wiring. –  Move bracket and wiring clear to the side. –  Unscrew bottom bolt securing starter -1-.

–  Remove bolts -1 ... 3- and detach pendulum support.

–  Unbolt heat shield for drive shaft (right-side) -arrows-.

–  Unbolt drive shafts (left and right) from gearbox flange shafts -A-.   Note Make sure you do not damage surface coating on drive shaft.

–  If fitted, remove small flywheel cover plate -A--arrows-.

–  Remove nuts -arrows-. –  Detach catalytic converter from turbocharger and secure catalytic converter to prevent it from falling to the ground.   Note To prevent damage, the flexible joints in the front exhaust pipe must not be bent further than 10°.   Note

In the following steps make sure that no brake fluid escapes onto the starter or onto the gearbox below. If this does happen, clean the affected area thoroughly. –  Using hose clamp -3094-, clamp off supply hose to master cylinder.

–  Pull clip -arrow- out as far as stop. –  Pull pipe/hose assembly -A- out of bleeder connection for slave cylinder and seal end of pipe.   Caution Do not operate clutch pedal after disconnecting pipe/hose assembly. –  Detach earth wire -B- from starter bolt (top). –  Then remove upper securing bolt from starter -B-. –  Place starter to side onto longitudinal member.

–  Remove bolts on gearbox mounting -arrows-.

–  By adjusting spindles on support bracket -10 - 222 A-, lower gearbox by distance -a-. l  Dimension -a- = 60 mm

–  Unbolt gearbox bracket from gearbox -arrows-.

Metal gate relay lever -1- –  Pull off securing clip -arrow- and remove gate relay lever -1-.

Plastic gate relay lever –  Press in detent -arrow 1- as far as stop and remove gate relay lever together with cable end-piece (move relay lever in normal direction of operation).   Note -Item 2- can be disregarded.

Continued for all vehicles –  If fitted, unbolt heat shield for power steering control unit -J500- from subframe -arrows-.

–  Drill two 7 mm diameter holes in support -T10036-, as illustrated (if holes have not already been drilled). l  Distance -a- = 11 mm l  Distance -b- = 98 mm l  Distance -c- = 70 mm

–  Bolt support -T10036- onto subframe -arrows- using two M6×20 bolts.

–  Bolt engine support -3300 A- onto support -T10036-.

–  Press engine towards front of vehicle using spindle of engine support -3300 A-. Pay special attention to the following points: l  The air conditioner compressor -2- must not contact refrigerant line -1--arrow-. l  Alternator must not make contact with refrigerant line. l  Pressure pipe must not make contact with radiator.

–  Remove flange bolt -2- and detach drive shaft (left-side) -1-.   Note The wheel bearing must not be subjected to load after the bolt -2- securing the drive shaft has been slackened.

–  Remove engine/gearbox connecting bolts (bottom) -4-.   Note Loosen engine/gearbox connecting bolt -3- and leave screwed in (hand-tight). To remove gearbox “02Q” set up gearbox support -3282- with adjustment plate -3282/33-. –  Fit gearbox support -3282- into engine/gearbox jack -V.A.G 1383A-. –  Align arms of gearbox support according to holes in adjustment plate.

–  Bolt on support elements -A-, as illustrated on adjustment plate. –  Screw in pin -3282/29- instead of support element-C-. –  Place engine/gearbox jack under vehicle; arrow symbol -B- on adjustment plate points to front of vehicle. –  Align adjustment plate and gearbox parallel to one another.

–  Secure adapter -VW 771/40- in tapped hole of gearbox housing, as shown in illustration. –  Screw pin -3282/29- into hole for bolt securing pendulum support to gearbox. –  Secure gearbox to gearbox support -3282- with bolt M10x20 -A-. Make sure pin -B- is flush at bottom with guide of gearbox support -3282--arrow-. –  Remove engine/gearbox connecting bolt -C-.

–  Remove last engine/gearbox connecting bolt -arrow-. –  Press gearbox off engine (dowel sleeves).

–  Tilt gearbox to the front by turning spindle of gearbox support -3282- in direction of -arrow-. –  Then tilt gearbox to the left by turning spindles of gearbox support -3282-. –  Guide gearbox past suspension bracket for wishbone, then push gearbox forwards slightly and lower out carefully. Installing gearbox → Chapter