Audi Workshop Service and Repair Manuals

Removing gearbox on vehicles with 4-cylinder TDI engine

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Gearbox support -3282-

t	Adjustment plate -3282/43-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

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

t  Wing compensation plate -T40045- t  Grease for clutch plate splines -G 000 100- t  Copper grease (commercially available) Procedure   Note t  All cable ties which are released or cut open during removal must be fitted in the same position when installing. t  Heat insulation sleeves removed during removal of gearbox must be fitted in the same position when installing.   Caution Follow steps required when disconnecting battery → Rep. Gr.27.

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

Vehicles with 1.9 ltr. TDI engine: –  Pull dipstick -1- out of guide tube. –  Unclip caps. –  Unscrew nuts -arrows- and detach engine cover. –  Remove insulation from beneath cover. –  Re-insert dipstick in guide tube.

Vehicles with 2.0 ltr. TDI engine: –  Pull off engine cover panel -arrows-.

Continued for all vehicles: –  Unbolt coolant expansion tank -arrow-. –  Unplug electrical connector for coolant shortage indicator switch -F66- at expansion tank (bottom) and move coolant expansion tank (with coolant hoses -1 … 3- attached) clear to one side.

–  If fitted, remove air cleaner cover -arrow-.

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

–  Unplug electrical connector -2- at air mass meter -G70-. –  Move wiring harness clear at air cleaner housing -arrows-. –  Detach air hose -3-. –  Unscrew bolt -1- and take out air cleaner housing.

Vehicles with 2.0 ltr. TDI engine: –  Move clear electrical wiring at fuel filter bracket. –  Unscrew nuts -arrows- and move fuel filter aside (with fuel hoses attached).

Continued for all vehicles: –  Remove upper engine/gearbox securing bolts -arrows 1- and -arrows 2-. Please note that there may be brackets for wires/lines located beneath the bolts -arrows 2- (important for installation).

–  Detach rubber seal from edges of wing mounting flanges. –  To avoid damaging edges of wing panels with support bracket -10-222 A-, insert wing compensation plates -T40045- on both sides between the wing mounting flange and the body panel underneath.

–  Set up support bracket -10-222 A- with adapters -10-222/3- on wing mounting flanges. –  Engage spindles on engine lifting eyes as illustrated. –  Take up weight of engine using spindles.

–  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-.

–  Detach bracket -arrow- for noise insulation.

Vehicles with particulate filter –  Unscrew bolts for front exhaust pipe bracket -arrows-. –  Remove front exhaust pipe behind particulate filter → Rep. Gr.26.

Continued for all vehicles: –  Remove noise insulation -1- in wheel housing (left and right).

–  Unbolt heat shield -arrow- for drive shaft (right-side) from gearbox. –  Unbolt drive shafts (left and right) from gearbox flange shafts.

–  Unscrew bolt -1- and nut -2-, and detach retaining bracket for front exhaust pipe (if fitted).   Note

The flexible pipe connection (de-coupling element) on the front exhaust pipe must not be bent more than 10° – otherwise it can be damaged. –  Separate the exhaust system at the clamp -arrow- and slide the clamp to rear.

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-.

–  Unscrew nuts -1- on left and right sides, and swivel anti-roll bar -2- downwards. –  Unscrew nuts -3- on engine mountings (left and right) until bottom of nut is flush with end of 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: –  Unscrew the three lower engine/gearbox securing bolts -arrow-. Cabriolet: –  Lower engine back down.

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

–  Drill a hole of 10.2 mm Ø -arrow- in the support elements of gearbox support -3282-.

–  To remove manual gearbox 01X, set up gearbox support -3282- with adjustment plate -3282/43- and place on engine and gearbox jack -V.A.G 1383 A-.   Note t  The support elements-arrows A- and -arrows B- are shown in schematic form on the adjustment plate. The arrow on the adjustment plate points in the direction of travel. t  Adjustment plate can only be fitted in one correct position.

–  Align the adjustment plate parallel to the gearbox. –  Secure support elements to left side of gearbox, as shown in illustration. Tighten bolt (M10 x 20) -arrow on right side- to 20 Nm.

–  Secure support elements to right side of gearbox, as shown in illustration. Tighten bolt (M10 x 20) -arrow on left side- to 20 Nm.

–  First remove bolts -1- and then bolts -2-.

–  Unscrew nuts -arrows- and detach tunnel cross member. –  Lower gearbox slightly with engine and gearbox jack -V.A.G 1383 A-.

–  Unplug electrical connector -arrow- for reversing light switch -F4- and move electrical wire clear.

–  Unscrew connecting rod -2- for selector rod. –  Unscrew push rod -1-, using an 8 mm hexagon key when unscrewing bolt.

–  Unscrew nut -arrow- and detach gearbox selector lever from selector shaft. –  Move wiring clear at top of 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 clutch slave cylinder.   Note When lowering gearbox, ensure hydraulic pipe/hose to slave cylinder is not damaged.

–  Remove clutch slave cylinder from gearbox -arrow- and secure with wire, do not open pipe/hose system.   Caution Do not depress clutch pedal after removing clutch slave cylinder. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N. –  If fitted, remove retaining clips/cable ties together with Lambda probe wires from top of gearbox. –  Lower gearbox.   Note When lowering gearbox, make sure there is sufficient clearance from drive shafts. –  Before carrying out assembly work, secure gearbox to assembly stand, using engine and gearbox support -VW 540- → Chapter.

–  If you will be installing a new gearbox instead of the one removed, the gearbox mounting has to be transferred to the new gearbox -arrows- → Anchor. Installing gearbox → Chapter