Audi Workshop Service and Repair Manuals

Removing gearbox (vehicles with 4-cylinder 2.0 ltr. TFSI engine)

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Rack -10 - 222 A /1-

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

t	Gearbox support -3282-

t	Shackle -10 - 222 A /12-

t	Hose clamps, up to 25 mm -3094-

t  Removal lever -80 - 200-

t  Pin -3282/29-

t  Adjustment plate -3282/42 A-

t  Engine bung set -VAS 6122-

t  Hose clip pliers -VAS 6340- Removing   Note t  → Chapter „Repair instructions“. t  → Chapter „Rules for cleanliness when working on the gearbox“. t  Observe notes on direct shift gearbox 02E → Chapter. t  Re-attach all cable ties at the same locations when re-installing. –  Switch off ignition.

There are two different versions of this engine. Version 1 (with air cleaner housing at side): –  Unplug electrical connector -1- from air mass meter -G70-. –  Remove air hose -2-. –  Remove bolt -4- and remove air cleaner housing.   Note -Item 3- can be disregarded.

–  Remove engine cover panel -arrows-.

Version 2 (with air cleaner housing in engine cover panel): –  Unplug electrical connector -3- from air mass meter -G70-. –  Release clamps -1 and 2- and disconnect air hose from air mass meter. –  Release spring-type clip -4- and detach air intake hose from engine cover panel.

Caution Risk of breaking engine cover panel. It is important to observe the removal sequence. –  Carefully detach engine cover panel from positions -1, 2, 3, 4- one after the other.

Continued for all vehicles: –  Shift selector lever into position “P”.   Caution When disconnecting the battery there is a risk of serious damage to electronic components: Observe the correct procedure for disconnecting the battery. –  Remove battery → Electrical system; Rep. Gr.27. –  Remove bolts -arrows- and detach battery tray.

–  Release securing clip -A- detach by pulling upwards. –  Press selector lever cable off gearbox selector lever -arrow- and move clear to the top. –  Remove bolts -1-.   Note t  Do not bend or kink the selector lever cable. t  Items -B, C and D- can be disregarded.

–  Remove starter → Electrical system; Rep. Gr.27.

–  Disconnect earth wire -3-.   Caution The control unit (mechatronic unit) can be damaged by electrostatic discharge. Do not touch contact pins in gearbox connector with bare hands. –  Touch vehicle earth with your hand (without gloves) to discharge any static electricity. –  Turn electrical connector -4- on gearbox to release it and then unplug it.   Note Items marked -1, 2- and -arrow- can be disregarded.

–  Mark coolant hoses leading to gear oil cooler to ensure correct connection when installing. –  Clamp off coolant hoses for gear oil cooler with hose clamps up to 25 mm -3094- and detach from gear oil cooler -A-. –  Seal off open lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Remove all engine/gearbox securing bolts which are accessible from above.   Note Bolt -item 3- is located in aperture for starter.

–  If necessary, lever clip off sealing element using removal lever -80 - 200- and fold up sealing element.

–  If there are hoses and cable connections in area of engine lifting eyes for support bracket -10 - 222 A-, remove these now. –  Set up support bracket -10 - 222 A- on wing mounting flanges (vehicles up to 05.2008) or on body flanges (vehicles from 05.2008 onwards), as shown in illustration. –  Partly take up weight of engine with spindle, but do not lift.

–  Raise vehicle. –  Remove noise insulation → General body repairs, exterior; Rep. Gr.50.   Note Depending on version, different types of noise insulation may be fitted.

–  Remove front section of front wheel housing liner on both sides → Rep. Gr.66.   Note Depending on version, different types of wheel housing liner may be fitted. –  Remove both front wheels.

–  If fitted, remove guard plate at bottom of gearbox -arrows-.

–  Unbolt support bracket for exhaust system -arrows-.

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

–  Detach electrical wiring and bracket from front of gearbox.   Note Bracket -A- is secured to front of gearbox oil pan.

–  Disconnect exhaust system at clamp -arrows-. –  Push clamp towards the rear. –  Tie up the front exhaust pipe.   Note The flexible joint (de-coupling element) in the exhaust system must not be bent more than 10° – otherwise it can be damaged.

–  Mark position of propshaft with flexible coupling in relation to bevel box flange. –  Unscrew propshaft with flexible coupling from bevel box flange -arrows-.   Note When slackening off bolts, counterhold propshaft flange/final drive with a suitable lever.

–  Press propshaft horizontally to rear as far as possible.   Caution t  When removing the gearbox, make sure the seal -arrow- in the propshaft flange is not damaged. If seal is damaged propshaft must be renewed. t  Slackening off bolts for pendulum support/subframe causes engine/gearbox assembly to swing forwards slightly.

–  Remove bolts -2- and -3-. –  Push the engine/gearbox assembly forward slightly and then pull the propshaft off the bevel box. –  Lift propshaft up and secure with wire. –  Locate subframe prior to removal → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. –  Remove subframe with pendulum support → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. –  Remove suspension bracket (left-side) with wishbone → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40.

–  If fitted, remove bracket for catalytic converter; to do so unscrew bolts -1- and -2-.

–  Unbolt heat shield for drive shaft (right-side) from bevel box -arrows-. –  Unbolt drive shafts (left and right) from gearbox flange shafts. –  Lift drive shaft (right-side) up and secure with wire. –  Move drive shaft (left-side) clear towards the rear and secure with wire.

–  Unscrew bolts for gearbox carrier on bevel box -arrows 1- and engine -arrows 2-.   Note Do not remove gearbox carrier until gearbox has been pressed off engine.

–  If fitted, remove small cover plate -A- at rear of bevel box -arrow-.

–  Unscrew bolts -1- and -2- and detach gearbox support -A-.

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

To remove direct shift gearbox 02E, set up gearbox support -3282- with adjustment plate -3282/42 A- and place on engine and gearbox jack -V.A.G 1383 A-. –  Align arms of gearbox support according to holes in adjustment plate -3282/42 A-. –  Secure support elements as illustrated on adjustment plate -3282/42 A-. However, use -retainer plate with drilling- as front support element. –  Place engine and gearbox jack -V.A.G 1383 A- underneath vehicle. l  The arrow symbol on the adjustment plate points in the direction of travel. –  Align gearbox support -3282- parallel with gearbox. –  Screw pin -3282/29- into gearbox. –  Secure -retainer plate with drilling- firmly to gearbox as illustrated -arrow-. –  Insert last support element in gearbox as illustrated. –  Support the gearbox by raising the engine and gearbox jack -V.A.G 1383 A- from below. –  Remove remaining engine/gearbox securing bolts. –  Press gearbox off dowel sleeves. –  Pull the gearbox off engine first from the bevel box side and then from the front side. –  Lower gearbox carefully using engine and gearbox jack -V.A.G 1383 A-; make sure no wires or hoses become trapped. –  When lowering the gearbox, change position of gearbox using the spindles on gearbox support -3282-.