Transmission, removing and installing (vehicles with 6-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.

Determine whether a coded radio is installed. In so, obtain anti-theft coding.
Remove engine cover.
Remove battery and battery holder. → 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Fig 1: Identifying Hoses & Bracket for Cooling Fluid Line Below Plenum Chamber

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If installed, disconnect hose - 1 - for crankcase ventilation from cylinder head cover.
Disconnect hose - 2 - for EVAP canister.
Press off bracket for cooling fluid line below plenum chamber - arrows -.

Fig 2: 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 -.
Remove intake hose - 1 - → 24 - MULTIPORT FUEL INJECTION (MFI) .

Fig 3: Identifying Speedometer Sensor Connector

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

Fig 4: Securing Locking Mechanism On Gear Selector Cable And Gate Selector Cable

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Pull securing mechanism on shift cable and on selector cable toward front to stop in direction of - arrow 1 - and then lock toward left in direction of - arrow 2 -.

Fig 5: Identifying Support Bracket At Transmission

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Remove cable mounting bracket from transmission - arrows -.
Tie up shift cable and selector cable.

Fig 6: Identifying Power Steering Line, Locking Washer, Actuator Lever, Transmission Shift Lever & Nut

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Disconnect power steering line - arrow 1 -.
Pull off locking washer - arrow 2 - from actuator lever - A - and remove actuator lever.
Remove transmission shift lever - B - by unscrewing nut - arrow 3 -.

Use extractor Kukko 20-10 if necessary.

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.

Fig 8: 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 9: 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 off hose to slave cylinder.
Pull off clamp - arrow - and hose/line assembly in direction of - arrow -.

NOTE:

Do not depress clutch pedal.

Remove upper connecting bolts for engine/transmission.
Remove hose and cable connections in area of engine lifting eyes for engine support bridge V.A.G 10-222A.

Fig 10: Support Bar 10-222A Together With Legs 10-222 A/1, Special Hook 10-222 A/2 And Adapter 10-222 A/3 (6-Cyl. Engines)

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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.
Remove right wheel.
Turn steering toward left.

Raise vehicle.
Remove sound insulation.
Remove radiator coolant fan and auxiliary coolant fan, if installed → 19 - ENGINE - COOLING SYSTEM .

Fig 11: Locating Left Sound Insulation & Bolts

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Remove left sound insulation - arrows -.
Remove right sound insulation.
Remove shielding plate for drive axle on right side.
Remove drive axles from flanged shafts and tie up as far away as possible so that protective coating is not damaged.

Disconnect exhaust system, remove double catalytic converter and remove front exhaust pipe from exhaust manifold → 26 - EXHAUST SYSTEM, EMISSION CONTROLS .
Disconnect power steering line from starter and from transmission.
Remove starter → 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Fig 12: Identifying 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 - arrows -.

Fig 13: Identifying Bevel Gear Transfer Case Bolt

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Remove bolt above bevel gear transfer case - arrow -.
Remove rear connecting bolt for engine/transmission at bottom.

Fig 14: Identifying Pendulum Support & Bolts

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Remove pendulum support - arrows A - and - arrows B -.
Mark position of driveshaft with flexible disc to bevel gear transfer case flange.

Fig 15: Identifying Bevel Gear Transfer Case Flange Bolts

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

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 lift far enough until transmission stands parallel to transmission mount.
Remove power steering reservoir from engine mount, but do not loosen hoses while doing this.

Fig 17: Locating Engine Carrier Bolts (Engine Side)

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Unbolt subframe mount from engine bracket - arrows - on engine side, from above.

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 under transmission.

Fig 19: Identifying Guide Pin For Driveshaft

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Carefully press engine/transmission toward front, so that pin on driveshaft flange lies free.
Carefully bring engine with transmission into tilt position by screwing down left spindle on engine support bridge 10 - 222 A approx. 60 mm.

Fig 20: Transmission Left Mount

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Remove left console - 1 - from transmission - arrows -.

Fig 21: Identifying Dimension Between Underside Of Left Subframe Mount & Bolting Surface Of Left Console On Transmission

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Lower engine/transmission via right and left spindles - arrows - of engine support bridge 10/222A to dimension - a - approx. 25 cm.

NOTE:

When lowering engine/transmission, pay attention to position of wiring harnesses.

Measure dimension - a - between underside of left subframe mount - 1 - and bolting surface of left console on transmission - 2 -.
Remove lower connecting bolts for engine/transmission.

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

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.

Fig 23: Identifying Engine/Transmission Jack V.A.G 1383 A With Transmission Support 3282 Under Vehicle

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Place engine/transmission jack V.A.G 1383 A under vehicle, - arrow symbol B - on adjustment plate points in direction of travel.
Align adjustment plate parallel to transmission.
Secure transmission on transmission support 3282 using bolt - A -.

Fig 24: Identifying Secondary Air Injection Pump Bracket, Engine & Connecting Bolt

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Remove Secondary Air Injection (AIR) pump bracket - 1 - from engine - arrows -.
Remove connecting bolt for engine/transmission - arrow A -.
Note intermediate plate at bottom on engine.
Press transmission from alignment bushings.

Fig 25: Identifying Transmission, Oil Pan, Bevel Gear Transfer Case & Bolting Eyelet

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Rotate transmission - 1 - upward in area of bevel gear transfer case - 3 - via spindles of transmission support VAS 3282.
Carefully guide transmission away from flywheel (ring gear for starter), press to subframe while doing this.
Set transmission to tilt toward left and downward via spindles of transmission support 3282 and lower slightly.
Guide bevel gear transfer case at bolting eyelet - arrow A - and at oil pan - 2 - as shown - arrow B -.

At same time, carefully press engine toward front with help of a second technician.

NOTE:

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

Fig 26: Identifying Transmission Support 3282 & Subframe

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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.