Transmission, Removing (CJAA) Engine: Notes

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For the 2.0L TDI, 103kW (CJAA) diesel engine.

Short description

The transmission is removed downward separately.

From above :

The battery, air filter and starter are removed. The steering gear wiring harness is disconnected and freed up. This way it can be lowered together with the subframe and the steering gear. Engine and transmission are supported before left subframe mounting is removed.

From underneath:

The -subframe-, with the -pendulum support-, with the -steering gear- and with -both control arms- are removed together.

Fig 1: Identifying Subframe Secured On Engine/Transmission Jack VAG 1383 A With Accompanying Strap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Both driveshafts are disconnected from the transmission and remain inside the wheel bearing housings. Occasionally they will be moved to the side, but they still remain on the vehicle.

Special Tools And Workshop Equipment Required

Transmission Support 3282
Adjusting Plate 3282/42 A
Bolt 3282/29
Torque Wrench 5-50 Nm VAG 1331
Torque Wrench 5-50 Nm VAG 1332
Engine-Transmission Jack VAG 1383 A
Engine Support Bridge 10 - 222 A
Hose Clamps up to 25 mm diameter 3094 and hose clamps, up to 40 mm 3093
Tensioning Strap T10038
Engine Support Basic Set T40091
Engine Support Supplement Set T40093
Engine Bung Set VAS 6122

Removing

-- Move the selector lever into "P".

Fig 2: Identifying Selector Lever In "P" Position

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-- Disconnect the battery ground cable. Refer to REMOVAL AND INSTALLATION .

-- Remove the engine cover. Refer to REMOVAL AND INSTALLATION .

-- Remove the air filter housing. Refer to REMOVAL AND INSTALLATION .

-- Remove the battery. Refer to REMOVAL AND INSTALLATION .

-- Remove the battery tray. Refer to REMOVAL AND INSTALLATION .

Fig 3: Identifying Battery Housing Bolts

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-- Remove the selector lever cable from the transmission -arrows-.

Fig 4: Identifying Lock Washers

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NOTE:

Use pliers to remove the lock washer. Do not use a sharp-edged lever. Otherwise the selector lever cable could get damaged.

If necessary, remove the cable bracket -2- and selector lever cable from the transmission. Remove the bolts -1- and the lock washer -3-.

Fig 5: Elector Lever Cable Bracket Bolts And Locking Washer

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Replace the bolts -1- and lock washers.

Bolt tightening specification -1-. Refer to SELECTOR MECHANISM ASSEMBLY OVERVIEW .

CAUTION:

Danger of damaging the selector lever cable.

Remove the selector level cable from the cable mounting bracket when lowering transmission.
Do not bend or kink the selector lever cable.

-- Place lint-free cloth on to transmission fluid cooler and transmission to absorb exiting coolant.

NOTE:

When engine is warm, the cooling system is under pressure.

Cover the cap on the reservoir with a cloth and open it carefully before removing the coolant hoses.

-- Clamp the coolant hoses with Hose Clamps 3093 or Hose Clamps up to 25 mm diameter 3094 and remove them from the transmission fluid cooler.

Fig 6: Clamping Off Coolant Hoses Using Clamps 3094

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-- Seal the transmission fluid cooler connections with plugs taken from the Engine Bung Set VAS 6122.

-- Remove the starter -A-. Refer to REMOVAL AND INSTALLATION .

Fig 7: Identifying Starter And Bayonet Catch

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Remove the lower bolt first.

CAUTION:

Risk of destroying DSG Transmission Mechatronic -J743- with static electricity.

Do not touch contacts in DSG Transmission Mechatronic -J743- connector with hands.

-- To discharge any static electricity, touch vehicle ground with hand (without wearing a glove). Refer to GENERAL REPAIR INFORMATION => Electrical Components .

-- Turn the Mechatronic connector -1- counter-clockwise and then disconnect it.

-- Remove all upper engine/transmission connecting bolts.

Fig 8: Identifying Special Tool T10179

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These tools are suitable for this.

Special Tools And Workshop Equipment Required

Bits T10099
Insert Tool 18 Mm T10179
Special Wrench T10035
Socket, Multi-Point Bit T10061

One bolt is located inside the hole for the starter -arrow-. Use Multi Point Bit XZN 14 Socket T10061 to remove the bolt.

Fig 9: Locating Bolt Inside Hole For Starter -Arrow-

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-- Disconnect any hoses and cables in the area of the Engine Support Bridge 10 - 222A lifting eyes on the engine.

-- Remove the plenum chamber cover. Refer to REMOVAL AND INSTALLATION .

-- Remove the lock carrier trim. Refer to DESCRIPTION AND OPERATION .