Audi Workshop Service and Repair Manuals

Separating engine and dual clutch gearbox 0B5 Special tools and workshop equipment required t  Support set for Audi -VAS 6131/10-, supplementary set -VAS 6131/13- and gearbox support -VAS 6131/14-

t  Adapter -T40058-

t  Socket Torx T 60 -T40087- t  Bolt M8x35 with washer (outer Ø 25 mm)

Procedure l  Engine/gearbox assembly removed and secured to scissor-type assembly platform -VAS 6131 A- –  Remove nuts -1, 2- and bolt -3- and detach front exhaust pipe.

–  Detach electrical connector -2- from bracket and unplug.   Note t  The illustration shows the installation position with the engine installed. t  Disregard -item 1-.

–  Unplug electrical connector -1- for exhaust gas temperature sender and move wiring clear. –  Remove bolts -2- and -3-. –  Detach heat shield for turbocharger.   Note The illustration shows the installation position with the engine installed.

–  Unplug electrical connectors -1- and -3-.   Note t  The illustration shows the installation position with the engine installed. t  Disregard -item 2-.

–  Remove nuts -arrows- for particulate filter and turbocharger. –  Detach particulate filter.

Caution Risk of irreparable damage to gearbox control unit (mechatronic unit) because of static discharge. t  Before unplugging or plugging in electrical connector, mechanic must „discharge static“ by briefly touching vehicle earth, heater or lifting platform. t  Do NOT touch connector contacts in gearbox connector with your hands. –  Turn retainer catch anti-clockwise -arrow- and unplug electrical connector at gearbox.

–  Remove bolts -1- and -3-. –  Loosen bolt -2- and move heat shield -B- clear to one side.   Note Disregard -item A-.

–  Unbolt drive shafts (left and right) from gearbox flange shafts → Rep. gr.40. –  Move electrical wiring for engine speed sender -G28- clear on gearbox.

–  Detach bottom cover -1- from gearbox -arrow-.

–  Insert guide pin of adapter -T40058- as follows: l  The larger-diameter section -arrow 1- faces towards the engine. l  The smaller-diameter section -arrow 2- faces the adapter.

–  Remove bolt -arrow- for ATF lines.   Note

Lay a cloth under the separating point to catch escaping ATF. –  Remove bolts -arrows- and detach ATF line -1- from gearbox.   Note Disregard -items 2, 3-.

–  Remove bolt -1-. –  Pull out securing clip -arrow- and disconnect ATF line from ATF filter.   Note Disregard -item 2-.

–  Tie up ATF lines -1- and -2-.   Note Disregard -item 3-. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Counterhold crankshaft using adapter -T40058- when slackening bolts for dual-mass flywheel.   Note When performing the next step, turn the crankshaft only in the normal direction of rotation -arrow-.

–  Remove 6 bolts -arrow- for dual-mass flywheel, turning crankshaft 60° in normal direction of rotation each time.

Caution If a used belt runs in the opposite direction when it is refitted, this can cause breakage. Before removing, mark direction of rotation of poly V-belt with chalk or felt-tip pen for re-installation. –  Slacken poly V-belt by turning tensioner in clockwise direction -arrow- using socket Torx T 60 -T40087-. –  Remove poly V-belt from tensioner and release tensioner.

–  Remove bolt -2- and pivot tensioner in clockwise direction -arrow-.   Note Disregard -item 1-.

–  Set up scissor-type assembly platform -VAS 6131 A- with support set for Audi -VAS 6131/10-, supplementary set -VAS 6131/13- and gearbox support -VAS 6131/14- as follows:   Note The other support elements remain unchanged.

Platform coordinates	Parts of support set for Audi -VAS 6131/10-, supplementary set -VAS 6131/13- and gearbox support -VAS 6131/14-
D2	/13-7
B10	/10-1	/10-2	/10-5	/14
G10	/10-1	/10-2	/10-5

–  Secure support -VAS 6131/13-7- in threaded hole for poly V-belt tensioner at front left of engine with M8x35 bolt and washer (outside diameter 25 mm), as illustrated. –  Secure support -VAS 6131/13-7- to scissor-type assembly platform.

Caution Risk of leaks at ATF sump. Do not apply gearbox support -VAS 6131/14- at ATF oil pan. –  Position support elements from -VAS 6131/10- and gearbox support -VAS 6131/14- at front of gearbox, as illustrated. –  Screw spindles on both sides upwards until gearbox support -VAS 6131/14- makes full contact with gearbox. –  Tighten base plates for support elements to 20 Nm on scissor-type assembly platform -VAS 6131 A-.

–  Remove bolts -1- and -2- for starter. –  Separate starter from gearbox and leave in position. –  Unscrew remaining bolts -3 ... 11- securing engine to gearbox.   Note Disregard -item A-.

–  Loosen clamping bolts -1- on sides of scissor-type assembly platform -VAS 6131 A- and pull rear section of platform together with gearbox towards rear -arrow-.