Transmission, Removing, 2.0L TDI Engine (Pr-TD1)

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Fig 1: Identifying Special Tools

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Special tools and workshop equipment required

Pry Lever 80-200
Engine and Gearbox Jack VAS6931
Used Oil Collection and Extraction Unit SMN372500 or VAG1782
Step Ladder VAS5085
Engine Bung Set VAS6122
Gearbox Support T40173

Special tools and workshop equipment required

Brake Piston Retraction Tool T40142

Fig 2: Brake Piston Retraction Tool T40142
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Procedure

Fig 3: Identifying Battery

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-- Position the front wheels so they are straight.

CAUTION:

Risk of damaging electronic components when disconnecting the battery.

Complete the steps for disconnecting the battery.

-- Disconnect the battery ground cable -2-. Refer to BATTERY, DISCONNECTING AND CONNECTING .

CAUTION:

Danger of damaging the engine cover.

Do not pull sharply on the engine cover or pull it to one side.

-- Carefully remove the engine cover from the retaining pins one after the other -arrows-. Do not pull sharply on the engine cover or pull it to one side.

Fig 4: Removing Engine Cover

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-- Remove the plenum chamber bulkhead. Refer to OVERVIEW - BULKHEAD .

-- Disconnect the connectors -1 and 2-.

Fig 5: Identifying Connectors -1 And 2-

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CAUTION:

There is a risk of destroying the Exhaust Pressure Sensor 1 -G450- and Differential Pressure Sensor -G505-.

If the pressure is too high the connection from the Exhaust Pressure Sensor 1 -G450- and Differential Pressure Sensor -G505- can break.

-- Remove the bolt -3- and push aside the bracket with the Exhaust Pressure Sensor 1 -G450- and Differential Pressure Sensor -G505-.

-- Remove the bolts -2 through 5- connecting the engine to the transmission. They are accessible from above.

Fig 6: Engine To Transmission Bolts And Alignment Sleeves

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NOTE:

The bolts -2- secure the bracket for the wires.

The bolt -2- attaches the starter to the transmission and has an additional spacer sleeve -arrow-.

Fig 7: Identifying Bolt & Spacer Sleeve

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-- Remove the noise insulations -1- and -2-. Refer to NOISE INSULATION .

Fig 8: Noise Insulation Panels

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-- Remove the left and right driveshaft cover -1- inside the wheel housing.

Fig 9: Driveshaft Cover -1-

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-- Remove the bolt -arrow- from the ATF pipe.

Fig 10: Identifying Bolt For ATF Line Bracket

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-- Remove the subframe crossbrace. Refer to OVERVIEW - SUBFRAME .

NOTE:

Lay a cloth under the separating point to prevent ATF from leaking out.

Fig 11: Removing ATF Pipes

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-- Remove the bolts -arrows- and then remove the ATF pipes -1- from the transmission and tie them up to the side.

-- Seal the open lines and connections with clean plugs from the Engine Bung Set VAS6122.

-- Remove the steering intermediate shaft from the steering gear and push them both upward. Refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

Fig 12: Identifying Steering Intermediate Shaft To Steering Gear Bolt

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CAUTION:

The suspension components could be damaged.

Do not rest the vehicle on its wheels if the subframe mount, the steering gear or the subframe crossbrace are not installed correctly.

-- Remove the lower cover -1- from the transmission -arrow-.

Fig 13: Identifying Transmission Lower Cover

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-- Remove the cap from the vibration damper.

Fig 14: Identifying Offset Open-End Wrench

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-- To loosen the flywheel bolts, counterhold the crankshaft with an offset open-end wrench -1- at the vibration damper.

NOTE:

When mounting, turn the crankshaft only in the direction of engine rotation -arrow-.

-- Remove the 3 flywheel bolts -arrow- while turning the crankshaft 120° further in the direction of engine rotation.

Fig 15: Identifying Clutch Module First Bolt Installation Location

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-- Remove the retaining tab screw -2-.

Fig 16: Identifying Bolt -2-, Removal

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-- Press the tab -1- in -direction of arrow B- and swivel it toward the rear -arrow A-.

NOTE:

the exhaust pipe remains installed.

-- Remove the bolts -arrows- and remove the heat shield from the right driveshaft.

Fig 17: Drive Axle Heat Shield & Bolts

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NOTE:

The illustration shows the installation position with the transmission removed.

-- Remove left and right driveshafts from transmission flange shafts.

-- Remove the ball socket -1- on the selector lever cable from the selector shaft lever using the Pry Lever 80-200.

Fig 18: Disconnect Electrical Connector On Transmission By Rotating Twist Lock Counter-Clockwise

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-- Remove the bolts -2- from the cable mounting bracket.

-- Free up the selector lever cable.

NOTE:

Do not bend or kink the selector lever cable.

CAUTION:

There is a risk of destroying the transmission control module (Mechatronic) with static discharge.

Always "discharge" the static electricity before working with electric connectors. Do this by touching a grounded object, for example vehicle ground, the vehicle or the hoist.
Do not touch contacts in transmission connector with hands.

-- Disconnect the connector from the transmission -arrow-.

-- Loosen the retainer -arrow-, push the release downward and disconnect the connector -2- from the Power Steering Control Module -J500-.

Fig 19: Power Steering Control Module & Connectors

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-- Free up the wiring harness.

NOTE:

Ignore -item 1-.

-- Remove the starter bolt -1-.

Fig 20: Engine To Transmission Bolts And Alignment Sleeves

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-- Remove the starter from the transmission and leave it in the installation position.

-- Remove the remaining bolts -6 through 10- that attach the engine to the transmission.

-- Place the Engine and Gearbox Jack VAS6931 with the Gearbox Support T40173 under the transmission and secure with the tensioning strap -1- as shown in the illustration.

Fig 21: Mounting Transmission Onto T40173 And Secure It Using Tension Strap

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-- Remove the tunnel crossmember. Refer to TUNNEL CROSSMEMBER, REMOVING AND INSTALLING .

-- Loosen the bolt -1- for the torque support -2-.

Fig 22: Identifying Torque Support And Bolts

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-- Only lower the transmission with the Engine and Gearbox Jack VAS6931 until the torque support is completely at the bottom of its adjustment range -arrow-.

-- Tighten the bolts and position the Brake Piston Retraction Tool T40142 as a spacer as shown in the illustration.

-- Press the transmission off the engine and lower it carefully using the Engine and Gearbox Jack VAS6931.

Fig 23: Mounting Transmission Onto T40173 And Secure It Using Tension Strap

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