Audi Workshop Service and Repair Manuals

Removing gearbox on vehicles with 4-cylinder engine

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Lifting tackle -2024 A-

t	Gearbox support -3282-

t	Adjustment plate -3282/10-

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

t	Grease for clutch plate splines -G 000 100-

t	Copper grease -Z 381 351 TE-

Procedure   Note All cable ties which are released or cut open during removal must be fitted in the same position when installing.   WARNING t  Follow steps required when disconnecting battery → Rep. Gr.27. t  On vehicles with telematics: activate service mode of telematics control unit before disconnecting battery → Rep. Gr.91. –  Refer to coding on vehicles with encoded radio/radio navigation system (RNS); obtain coding if necessary.

–  With the ignition switched off, disconnect battery earth strap.

Vehicles with 4-cylinder petrol engine: –  Pull off engine cover in direction of arrows.

Vehicles with 4-cylinder diesel engine: –  Pull dipstick -1- out of guide tube. –  Unclip cover caps. –  Unscrew nuts -arrows- and detach engine cover. –  Re-insert dipstick in guide tube.

–  Unclip cover caps. –  Unscrew bolts -arrows- and detach air cleaner cover.

–  Remove bolts -arrows-. –  Remove air ducts -1- and -2-.

–  Unplug electrical connector -2- at air mass meter. –  Move wiring harness clear at air cleaner housing -arrows-. –  Detach air hose -3-. –  Unscrew bolt -1- and take out air cleaner housing.

–  Unscrew securing nuts for turbocharger/catalytic converter -arrows-. Continued for all vehicles with 4-cylinder engine –  Unscrew engine/gearbox securing bolts accessible from above.

–  Set up support bracket -10 - 222 A- with racks -10 - 222 A /1-. –  Take up some of the weight of the engine by means of the spindle.

–  On vehicles fitted with auxiliary heater, remove bolts -arrows- securing exhaust pipe of auxiliary/ additional heater to noise insulation.

–  Loosen bolts/quick release fasteners -1- and -2- and remove front noise insulation -A-. –  If fitted, loosen quick release fasteners -3- and remove rear noise insulation -B-.

–  Unbolt bracket for noise insulation -arrow-.

–  Detach heat shields -arrow 1- and -arrow 2- above right-hand drive shaft.

–  If fitted, remove bolts -arrows- and detach covers -1- and -2-.

–  Remove tunnel cross piece (front) -1--arrows-. –  Remove front exhaust pipe -3- in front of clamp -2- → Rep. Gr.26. –  Remove heat shield -4- above exhaust system. Cabriolet:   Note On Audi Cabriolet vehicles the following additional steps are required in order to remove the three bottom engine/gearbox bolts:

–  Unbolt torque reaction support -arrows-.   Note On Cabriolet vehicles with 4-cylinder TDI engine, a torque reaction stop is fitted instead of the torque reaction support. In this case unbolt the torque reaction stop.

–  Unscrew nuts -1- on left and right sides, and swivel anti-roll bar -2- downwards. –  Unscrew nuts -3- on left and right engine mounting until bottom of nut is flush with stud -arrow-. –  Use support bracket -10 - 222 A- to lift engine just enough for nuts -3- to make contact with bottom surface of left and right console for engine mounting. Continued for all vehicles with 4-cylinder engine

–  Unscrew the three bottom engine/gearbox securing bolts -arrow-. Cabriolet: –  Lower engine to original position. Continued for all vehicles with 4-cylinder engine

–  Remove drive shafts -1- from flange shafts and tie up to side.   Note Make sure you do not damage surface coating on drive shafts. –  Take up some of the weight of the gearbox with engine and gearbox jack -V.A.G 1383 A-. –  First remove bolts -2- and then bolts -3- at tunnel cross member. –  Unscrew two nuts -4- and detach tunnel cross member. –  Lower engine and gearbox jack -V.A.G 1383 A- and move it aside.

–  Remove selector rod -arrow A-. –  Unscrew hexagon socket head bolt on push rod -arrow B-.

–  If fitted, pull connector -1- out of bracket -arrow-. –  Unplug connector and move wiring -2- clear.

–  Unplug connector from speedometer sender -G22--arrow A-. –  Unplug connector from reversing light switch -F4- (multi-function sender) -arrow B-. –  Disconnect all other electrical connections and earth wires from gearbox and from engine/gearbox securing bolts.

–  If fitted, remove engine speed sender -G28- from left of gearbox -arrow- and move clear.

–  Unbolt starter from engine/gearbox and secure as necessary → Rep. Gr.27.   Note Starter cables do not have to be disconnected.

–  Unscrew bottom engine/gearbox securing bolts, except for bolts indicated by arrows -A- and -B-.

–  Set up gearbox support -3282- with adjustment plate -3282/10- to remove manual gearbox 012, and place gearbox support on engine and gearbox jack -V.A.G 1383 A-. A -  Support elements   Note t  Support elements -A- are shown in schematic form, arrow -B- points in the direction of travel. t  Adjustment plate -3282/10- can only be fitted in one correct position.

–  Place gearbox jack under vehicle; arrow symbol -B- on adjustment plate points to front of vehicle.

–  Align adjustment plate parallel to gearbox and lock safety support -arrow- on gearbox.

–  Remove remaining engine/gearbox securing bolts -arrow A- and -arrow B-. –  Press gearbox off dowel sleeves and lower carefully with engine and gearbox jack -V.A.G 1383 A- just far enough to gain access to the clutch slave cylinder.   Note When lowering gearbox, ensure pipe/hose to slave cylinder is not damaged.

–  Remove slave cylinder -arrow- and secure with wire, do not open pipe/hose system.   Note Do not depress clutch pedal after removing slave cylinder. Otherwise, the piston will be pressed out of the slave cylinder and be destroyed. –  Lower gearbox completely.   Note When lowering gearbox ensure there is sufficient clearance from drive shafts. Before carrying out assembly work, secure gearbox to assembly stand with gearbox support -VW 353- and retaining plate -VW 309- → Chapter.

–  If the removed gearbox is being renewed, the gearbox support and gearbox mounting must be transferred to the replacement gearbox. Installing gearbox → Chapter