Transmission, removing and installing (vehicles with 4-cylinder engine): Removing

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Remove engine cover.
Determine whether a coded radio is installed. If so, obtain anti-theft coding.
Disconnect battery Ground (GND) strap with ignition switched off. → 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Fig 1: Identifying Air Cleaner Housing & Components

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Disconnect intake hose - 1 - , connector - 2 - and hose - 3 - from Mass Air Flow (MAF) sensor.
Remove complete air filter housing by removing bolts - 4 - and - 5 - → 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWD (A4 PLATFORM), 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): AWW, AWP (A4 PLATFORM), 24 - MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO GENERIC SCAN TOOL, ENGINE CODE(S): AWP, AWW, AWD (A4 PLATFORM), 24 MULTIPORT FUEL INJECTION (MFI) for 2.0 LITER 4-CYL. 2V ENGINE MECHANICAL, FUEL INJECTION & IGNITION, ENGINE CODE(S): AEG, AVH, AZG, BBW, BEV (A4 PLATFORM) and 24 - MULTIPORT FUEL INJECTION (MFI) for 2.0 LITER 4-CYL. 2V GENERIC SCAN TOOL, ENGINE CODE(S): AEG (A4 PLATFORM) .
Remove intake hose - 1 -.
Remove battery and battery holder. → 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Fig 2: Identifying Support Bracket At Transmission

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Remove cable mounting bracket from transmission - arrows -.

Fig 3: Gate Selector Cable Relay Lever, Lock Washer, Gear Selector Cable, Nut & Power Steering Line

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Pull locking disc - arrow 1 - from actuator lever of selector cable - A -.
Remove shift cable - B - with transmission shift lever; remove nut - arrow 2 - to do this.

For this task, use a two arm puller , e.g. Kukko 20/10 if necessary.

Disconnect power steering line - arrow 3 -.

Fig 4: Identifying Speedometer Sensor Connector

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Disconnect connector for Speedometer Vehicle Speed Sensor (VSS) - arrow -.

Fig 5: Starter Wiring, Back-up Light Connector, Starter Cable Retainer & Starter Upper Securing Bolt

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Disconnect wire - arrow 1 - from starter.
Disconnect connector for back-up lights - arrow 2 -.
Remove cable bracket - A - on starter - arrow 3 -.
Remove upper securing bolt on starter.

Fig 6: Identifying Special Tool 3094 On Clutch Slave Cylinder Hose & Pulling Out Clamp And Line/Hose

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Use Hose Clamp 3094 to clamp hose to slave cylinder.
Pull off clamp - arrow - and hose/line assembly in direction of - arrow -.

NOTE:

Do not depress clutch pedal.

Fig 7: Identifying Ground Strap At Engine/Transmission Upper Securing Bolt

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Remove Ground (GND) strap from connecting bolt at top of engine/transmission - arrow -.
Remove upper connecting bolts for engine/transmission.

Fig 8: Support Bar 10-222A Together With Legs 10-222 A/1, Special Hook 10-222 A/2 And Adapter 10-222 A/3 (4-Cyl. Engines)

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Remove any hose and cable connections found in area of engine lifting eyes for engine support bridge V.A.G 10-222A.
Attach Engine support bridge V.A.G 10-222A in conjunction with brackets for engine V.A.G 10-222A/1 , additional hooks V.A.G 10-222A/2 and adapters V.A.G 10-222A/3.
Take up weight of engine/transmission assembly on spindles.
If installed, remove lines and cable from transmission.

Steer wheels toward left.
Raise vehicle.

Fig 9: Locating Sound Insulation Tray & Bolts

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Remove sound insulation - arrows -.

Fig 10: Locating Left Sound Insulation & Bolts

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Remove left sound insulation - arrows -.
Remove right sound insulation.
Remove charge air pipe between charge air cooler and turbocharger → 21 - TURBOCHARGER, G-CHARGER for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP (A4 PLATFORM), 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH (A4 PLATFORM) and 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW (A4 PLATFORM) .
Unscrew left drive axle from transmission flanged shaft, bring upward and secure.

Remove right drive axle → 40 FRONT SUSPENSION .
Disconnect exhaust system, remove catalytic converter and front exhaust pipe from exhaust manifold and on turbocharger → 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP (A4 PLATFORM), 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH (A4 PLATFORM), 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW (A4 PLATFORM) and 26 EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 2V ENGINE MECHANICAL, FUEL INJECTION & IGNITION, ENGINE CODE(S): AEG, AVH, AZG, BBW, BEV (A4 PLATFORM) .

Fig 11: Identifying Pendulum Support & Bolts

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Remove pendulum support - arrows A - and - arrows B -.
Disconnect power steering line from starter and from transmission.
Remove starter → 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .
Mark position of driveshaft with flexible disc to bevel gear transfer case flange.

Fig 12: Identifying Bevel Gear Transfer Case Flange Bolts

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Unbolt driveshaft with flexible disc from bevel gear transfer case flange - arrows -.

Fig 13: Identifying Vacuum Diaphragm & Oil Return Line

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Unscrew vacuum diaphragm - 1 - for charge pressure regulator valve from turbocharger - arrows - and tie up → 21 - TURBOCHARGER, G-CHARGER for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP (A4 PLATFORM), 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH (A4 PLATFORM) and 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW (A4 PLATFORM) .
Place drip tray underneath transmission and engine.
Unbolt oil return line - 2 - for turbocharger from engine → 21 - TURBOCHARGER, G-CHARGER for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP (A4 PLATFORM), 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH (A4 PLATFORM) and 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW (A4 PLATFORM) .

Fig 14: Engine & Bevel Gear Transfer Case Bolts

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Unscrew transmission carrier for bevel gear transfer case from engine and bevel gear transfer case, bolts - A - , - B - and - C -.

NOTE:

Transmission carrier cannot be removed yet. Leave transmission carrier in installed position.
If installed, remove turbocharger bracket → 21 - TURBOCHARGER, G-CHARGER for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP (A4 PLATFORM), 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH (A4 PLATFORM) and 21 - TURBOCHARGER, G-CHARGER for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW (A4 PLATFORM) .

Fig 15: Small Cover Plate For Flywheel Behind Bevel Gear Transfer Case

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If installed, remove small cover plate - A - for flywheel behind bevel gear transfer case - arrow -.

Fig 16: Identifying Engine/Transmission Jack V.A.G 1383/A With Universal Mount V.A.G 1359/2 Under Transmission

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Place engine/transmission jack V.A.G 1383/A with universal mount V.A.G 1359/2 under transmission and press lightly against.

Fig 17: Locating Engine Carrier Bolts (Engine Side)

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Remove bolts for subframe mount from engine mount - arrows -.

NOTE:

Use step ladder VAS 5085 or equivalent to loosen mounting bolts.

Fig 18: Left Assembly Mounting Hex Bolts & Left Mount

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Remove hex bolts - arrows - of left subframe mount - 2 - from left console - 1 -.

NOTE:

Use step ladder VAS 5085 or equivalent to loosen mounting bolts.

Remove engine/transmission jack V.A.G 1383/A with universal mount V.A.G 1359/2 from under transmission.
Carefully push engine/transmission toward front.

Fig 19: Identifying Guide Pin For Driveshaft

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Guide pin - arrow - for driveshaft must lie free.

Carefully bring engine with transmission into tilt position. To do so, screw down left spindle on engine support bridge V.A.G 10-222A approx. 60 mm.

Fig 20: Transmission Left Mount

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Remove left console - 1 - from transmission by removing bolts - arrows -.

Fig 21: Identifying Selector Cable

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Pull off selector cable - A - with actuator lever in direction of arrow.
Tie up shift cable with transmission shift lever and selector cable with actuator lever.
Bring engine/transmission assembly further into tilt position by lowering left spindle of engine support bridge V.A.G 10-222A.
Remove rear connecting bolt for engine/transmission at bottom.

Remove lower connecting bolts for engine/transmission.

Transmission support 3282 must be equipped with adjustment plate 3282/27 to remove transmission "02Y".

Insert transmission support 3282 in engine/transmission jack V.A.G 1383 A.
Align transmission support arms to correspond with holes in adjustment plate.

Fig 22: Bolting Transmission Support Elements

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Screw in attachments - A - , as depicted on adjustment plate.
Align adjustment plate parallel to transmission.
Place engine/transmission jack V.A.G 1383 A under vehicle; - arrow symbol B - on adjustment plate points in direction of travel.

Fig 23: Transmission & Transmission Support 3282 With Bolt

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Secure transmission on transmission support 3282 using bolt - A -.
Remove connecting bolt for engine/transmission - arrow -.
Press transmission off alignment bushings and carefully swing toward subframe.
Remove transmission carrier for bevel gear transfer case.

Lower transmission slightly and tilt toward left via spindles of transmission support 3282.

Fig 24: Identifying Corner Of Oil Pan

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When lowering transmission - 1 - , pay attention to corner - arrow - of oil pan - 2 -.
Change position of transmission via spindles of transmission support 3282 so that bevel gear transfer case can be guided past at oil pan.
Carefully press engine toward front with help from a 2nd technician.

NOTE:

While shifting engine/transmission subframe, pay attention to all connecting lines and hoses.

Fig 25: Identifying Subframe

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Carefully lower transmission, paying attention to subframe while doing this - arrow -.
Change position of transmission by lowering via spindles of transmission support 3282.

NOTE:

Pay attention to power steering line when lowering transmission.