Audi Workshop Service and Repair Manuals

Removing gearbox on vehicles with 2.0 ltr. TDI engine (common rail)

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 /11-

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

t	Adapter -T40093/6-

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 When disconnecting the battery there is a risk of serious damage to electronic components: Observe the correct procedure for disconnecting the battery → Electrical system; Rep. Gr.27.

–  Press release tab -arrow- and remove cover -1- over battery. –  With ignition switched off, disconnect and remove battery → Rep. Gr.27.

–  Carefully detach engine cover panel from retaining studs -arrows- one by one. Pull out engine cover panel evenly, without jerking.

–  Remove air cleaner housing → Rep. Gr.23. –  Press release tabs and disconnect crankcase breather hose -1- from cylinder head cover. –  Move clear vacuum hoses -arrows- at air pipe. –  Release hose clip -2- and detach air pipe.

–  Remove bolts -arrows- and take out battery mounting -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.

–  Unscrew top engine/gearbox securing bolts -arrows-.

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

–  Detach seal -1-.   Note -Item 2- can be disregarded.

–  Swivel bonnet seal -1- inwards on left and right -arrow- –  Press off fastening element -2- with removal lever -80 - 200-. –  Move clear bonnet seal and press to the side.

–  Position support bracket -10 - 222 A- on wing mounting flanges with adapter -T40093/6-. –  Engage hooks on spindles of support bracket into engine lifting eyes. –  Take up weight of engine evenly with spindles; 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. –  Remove the left front wheel. –  Remove noise insulation (centre) -1- → Rep. Gr.50.

Audi A3 Cabriolet –  Remove frame for noise insulation -arrow- → Rep. Gr.50.

Continued for all vehicles –  Remove wheel housing liner (front left) -fasteners 1 ... 3-.

–  Lift retaining clip -1- and loosen hose clip -2- to remove air hose.

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

–  Unplug connector -2- from reversing light switch -F4-. –  Unscrew nut -1- and detach bracket from stud together with electrical wiring. –  Unscrew bottom bolt securing starter -1-. –  Place starter to side onto longitudinal member (top).

–  Disconnect exhaust system at clamp -arrows-.   Note To prevent damage, the flexible joints in the front exhaust pipe must not be bent further than 10°.

–  Unbolt bracket for exhaust system -arrows- and pull bracket off retaining pins.

–  Unplug electrical connector -1- at oil level and oil temperature sender -G266-. –  Unclip bracket -2- for electrical wiring leading to oil level and oil temperature sender -G266- at subframe.

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

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

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

–  Unscrew bolt -arrow- and remove small flywheel cover plate -A-.   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  Distance -a- = 60 mm   Note t  When lowering the gearbox make sure that all hose and pipe connections are not under tension. t  Pay attention to coolant hose between engine and heat exchanger, do not overstretch.

–  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).

Continued for all vehicles –  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 both engine/gearbox connecting bolts (bottom) -2-.

–  Set up gearbox support -3282- on engine and gearbox jack -V.A.G 1383 A-. –  Place adjustment plate -3282/33- on gearbox support -3282-. The adjustment plate can only be fitted in one position. –  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 and gearbox jack underneath vehicle. l  Arrow symbol -B- on adjustment plate points to front of vehicle. –  Align adjustment plate parallel with gearbox.

–  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