Gearbox removal & installation: VW 2.0 TDI (AZV, BKD, BMN)

🧭 Before you start

Fits: VW Touran I (1T, 2003–2015), VW Golf V / Jetta (1K, 2003–2009); platform code 5M1

• Opens: coolant
• Special tools named: VAS 5051, VAS 5052, VAS 5085

Don't miss

• To prevent damage to condenser and also to refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
• The engine is lowered downwards with particulate filter fitted.
• Support pins must be secured to engine bracket T10012 as shown. The threaded support pin must be on the gearbox side.
• To remove securing bolts, use stepladder VAS 5085.Engine with gearbox must be guided carefully when lowered to prevent damage to bodywork.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📐 74 workshop diagrams for AZV

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Read fault memories of all control units before removal Diagnosis tester VAS 5051; Guided fault finding; Vehicle system test or VAS 5052; Vehicle self-diagnosis.
2. With ignition switched off, disconnect earth strap from battery. Electrical system27Disconnecting and reconnecting batteries.
3. Remove engine cover.
4. Remove plenum chamber bulkhead. General body repairs, exterior50Body - front, plenum chamber bulkhead.
5. Remove air filter housing with air mass meter and connecting pipe.

6. Remove battery and battery tray.
7. Remove insulation tray General body repairs, exterior50Body - front; Assembly overview - noise insulation.
8. Bring lock carrier into service position General body repairs50Body - front; Lock carrier service position.
9. Drain coolant
10. ⚠ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure!Wear eye and hand protection when performing any type of repair work on the fuel system! — Disconnect fuel supply and return lines as well as coolant line on cylinder head.
11. Pull fuel filter module upwards out of bracket and lay it with hoses to side. [Note: To prevent damage to condenser and also to refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.]
12. Remove poly V-belt .
13. Separate air conditioner compressor from compact bracket. Heating, air conditioning87Removing and installing compressor bracket.
14. Secure air conditioner compressor to lock carrier so that refrigerant lines are relieved.
15. Remove exhaust pipe and coolant hoses from supplementary heater.
16. Remove connecting pipes between charge air cooler and engine.
17. Pull retainer for wiring harness of oil level and oil temperature sender G266 off subframe.
18. Remove right drive shaft and unscrew left drive shaft from gearbox Running gear, axles, steering40Removing and installing drive shaft.
19. Remove left wheel housing liner.
20. Disconnect front exhaust pipe from turbocharger, loosen double clamp and slide exhaust pipe back .
21. Pull engine wiring harness connector off control unit:
22. Open cable guide catches on longitudinal member (arrows).
23. Remove wiring harness from cable guide and lay to side on engine.
24. Separate connections at engine bulkhead for:
25. Pull off or disconnect all other electrical connections from engine and gearbox as necessary and lay to side.
26. Separate all connecting, coolant, vacuum and intake hoses from engine.
27. Release connecting clamp for front exhaust pipe/front silencer.
28. Remove subframe and steering Running gear, axles, steering40. [Note: The engine is lowered downwards with particulate filter fitted.]
29. Disconnect front exhaust pipe from turbocharger, loosen double clamp and slide exhaust pipe back .
30. Disconnect selector mechanism from gearbox 6-speed manual gearbox 02Q34.
31. Separate pressure line for hydraulic clutch control.
32. Remove pendulum support.
33. Insert engine bracket T10012 in engine and gearbox jackV.A.G 1383/A. [Note: Support pins must be secured to engine bracket T10012 as shown. The threaded support pin must be on the gearbox side.]
34. Fit engine bracket T10012 to cylinder block with M10 x 25/ 8.8 bolt and tighten to approx. 40 Nm. — 40 Nm (30 lb-ft)
35. Lift engine and gearbox lightly using engine and gearbox jackV.A.G 1383/A.
36. Unbolt engine side of assembly mounting from engine support from above (arrows).
37. Unbolt gearbox side of assembly mounting from gearbox bracket from above (arrows). [Note: To remove securing bolts, use stepladder VAS 5085.Engine with gearbox must be guided carefully when lowered to prevent damage to bodywork.]
38. Carefully lower engine with gearbox.

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