Removing and installing gearbox, 6-cylinder petrol engine — VW

Removing and installing gearbox, 6-cylinder petrol engine
Special tools and workshop equipment required
Support bracket
10-222A
Hook
10-222A/2
Adapter
10-222A/3
Shackle
10-222A/12
Adapter
10-222A/16
Adapter
10-222A/23
Hose clamps to 25 mm
3094
Gearbox support
3282
Adjustment plate
3282/47
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Engine and gearbox jack
V.A.G 1383 A
with
universal gearbox support
V.A.G 1359/2
Special tools and workshop equipment required
Drip tray for workshop hoist
VAS 6208
Spring-type clip pliers
V.A.G 1921
Angle wrench
V.A.G 1756
Step ladder
VAS 5085
Polycarbamide grease
G 052 142 A2
All-purpose grease
G 052 735
Removing
Remove engine compartment cover.
Remove lock carrier covers above headlights.
With ignition switched off, disconnect battery earth strap
Electrical system
Rep. gr.
27
Disconnecting and connecting battery
.
Remove plenum chamber cover
General body repairs, exterior
Rep. gr.
64
Bonded windows; Removing and installing plenum chamber cover
.
Remove left and right plenum chamber bulkhead panels from plenum chamber
General body repairs, interior
Rep. gr.
50
Assembly overview – plenum chamber bulkhead
.
Remove coolant expansion tank
1
Rep. gr.
19
Cooling system/coolant
.
Pull connector off bracket for vacuum reservoir
3
.
Remove bracket for vacuum reservoir
3
from plenum chamber.
Remove noise insulation
4
from plenum chamber at front.
Detach fuel hoses
1
from retainer on battery housing and from bracket
2
.
Unlock and pull off ABS control unit connector
3
.
Swivel coolant hose
1
upwards
arrow
, and lay it down on connector of ABS control unit
2
.
Unscrew bolts
2
from support bracket for selector lever cable.
Remove selector lever cable
1
from lever/selector shaft by hand.
Do not kink or bend selector lever cable.
In order to insert
hook
10-222A/2
into support eye at rear of engine, first remove intake hose
1
and connector
2
.
Remove intake hose
1
.
Pull connector
2
out of holder and put it to one side.
Remove protective caps for suspension struts.
Fit
adapters
10-222A/23
onto suspension struts
arrow A
at rear and onto lock carrier
arrow B
at front.
Secure
support bracket
10-222A
in conjunction with
adapter
10-222A/3
and
adapter
10-222A/16
left and right onto
adapters
10-222A/23
.
If there are hose and cable connections in area of engine support eye for
support bracket
10-222A
, remove these.
Attach
hook
10-222A/2
in rear support eye of engine.
Slightly preload engine/gearbox assembly using
spindle
10-222A/11
and
adapter
10-222A/16
.
Remove front left and front right wheel bolts.
Raise vehicle.
Remove front wheels.
Remove noise insulation below engine/gearbox.
Remove noise insulation for left and right drive shafts from wheel housing.
Remove exhaust system from subframe.
Remove subframe, noting that subframe needs to be secured
Running gear, axles, steering
Rep. gr.
40
Removing and installing subframe
.
Press left drive shaft off gearbox stub shaft, and secure it to body
Running gear, axles, steering
Rep. gr.
40
Removing and installing drive shafts
.
Remove right drive shaft
A
from torque reaction support
arrows
of engine. Pull drive shaft off gearbox stub shaft, and secure it to body.
Position
drip tray for workshop hoist
VAS 6208
under vehicle.
Unscrew nut
arrow
of ATF lines and pull ATF lines out of gearbox.
Seal gearbox connections and ATF lines with clean plugs.
Unlock and pull off connectors
1
and
2
of both gearbox wiring harnesses.
Remove starter motor
Electrical system
Rep. gr.
27
Starter; Removing and installing starter
.
Position
engine and gearbox jack
V.A.G 1383/A
with
universal support
V.A.G 1359/2
under final drive and exert slight counter pressure.
Remove hexagon bolts
arrows A
of left assembly mounting.
Remove
engine and gearbox jack
V.A.G 1383/A
with
universal support
V.A.G 1359/2
from under final drive.
Now step onto
step ladder
VAS 5085
to lower engine/gearbox assembly using adapter and spindle.
Using
adapter
10-222A/16
and spindle of
support bracket
10-222A
, lower engine/gearbox assembly to dimension
a
.
Dimension a = about 120 mm
Note
Measure dimension
a
between lower side of longitudinal member
1
and bolting surface of assembly mounting
2
.
Then unscrew assembly mounting
arrows B
from gearbox.
Note
Assembly mounting of gearbox is secured with three bolts. The third bolt is not visible in the figure.
Unhook both hydraulic lines for power steering from retainer
A
next to left longitudinal member.
Unbolt torque converter from drive plate
arrow
.
Turn crankshaft
1
6
turn for each bolt.
Remove engine/gearbox connecting bolt in area of support bracket for selector lever cable in starter mounting.
Remove front lower engine/gearbox connecting bolts.
To remove automatic gearbox 09K, set up
gearbox support
3282
with
adjustment plate
3282/47
.
Insert
gearbox support
3282
in
engine and gearbox jack
V.A.G 1383/A
.
Align arms of
gearbox support
according to holes in
adjustment plate
.
The symbols on the adjusting plate indicate the mounts required; the arrow points forward.
Position
engine and gearbox jack
V.A.G 1383/A
with
gearbox support
3282
under vehicle.
Take nut
2
that was used for securing ATF lines and screw it back on the
“other way round”
. The flange of the nut faces away from the gearbox.
Secure arm of
gearbox support
3282
onto gearbox with another nut
1
.
Insert pin of
gearbox support
3282
into final drive support
arrow
.
Remove rear engine/gearbox connecting bolts
arrows
.
Press gearbox off engine (dowel sleeves). At the same time, push torque converter in direction of
arrow
out of drive plate.
Secure torque converter against falling out
Chapter
.
Slowly lower gearbox with
engine and gearbox jack
V.A.G 1383/A
.
Comply with procedure for transporting automatic gearbox
Chapter
.
Installing
Install in reverse order of removal, observing the following:
Note
Clean ATF cooler and ATF lines before installing an exchange gearbox
Chapter
.
Before installing gearbox, ensure that torque converter seats correctly in gearbox
Chapter
.
Before installation, check dowel sleeves are correctly installed and seated properly.
Missing dowel sleeves result in misalignment of the axes of engine and gearbox, leading to destruction of the sleeve bearing and torque converter hub.
Turn torque converter and drive plate so that one threaded pin in torque converter and one hole in drive plate are centred in access hole of gearbox housing.
Renew retaining ring on left stub shaft if same gearbox is being reinstalled.
At same time, press old retaining ring out of stub shaft with new retaining ring
arrow
.
Lubricate left and right stub shaft splines with
all-purpose grease
G 052 735
.
Always renew self-locking nuts and bolts.
Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.
To install automatic gearbox 09K, set up
gearbox support
3282
with
adjustment plate
3282/47
.
Insert
gearbox support
3282
in
engine and gearbox jack
V.A.G 1383/A
.
Align arms of
gearbox support
3282
according to holes in
adjustment plate
3282/47
.
The symbols on the adjusting plate indicate the mounts required; the arrow points forward.
Position
engine and gearbox jack
V.A.G 1383/A
with
gearbox support
3282
under vehicle.
Take nut
2
that was used for securing ATF lines and screw it back on the
“other way round”
. The flange of the nut faces away from the gearbox.
Secure arm of
gearbox support
3282
onto gearbox with another nut
1
.
Insert pin of
gearbox support
3282
into final drive support
arrow
.
Position gearbox and align it with engine.
Screw in one engine/gearbox connecting bolt hand-tight on each side.
Screw on torque converter and drive plate with new nuts.
Tighten new torque converter nuts
arrows
on drive plate.
Turn crankshaft
1
6
turn for each bolt.
Tighten rear engine/gearbox connecting bolts.
After gearbox has been bolted to engine, remove
gearbox support
3282
from gearbox.
Tighten lower front engine/gearbox connecting bolts.
Install starter motor
Electrical system
Rep. gr.
27
Starter; Removing and installing starter
.
Hook both hydraulic lines for power steering into retainer
A
next to left longitudinal member.
Secure assembly mountings to gearbox with bolts
arrows B
.
Note
Assembly mounting of gearbox is secured with three bolts. The third bolt is not visible in the figure.
Now step onto
step ladder
VAS 5085
to raise engine/gearbox unit using adapter and spindle.
Align engine/gearbox in installation position. To do this, tighten threaded spindle of
adapter
10-222A/16
and spindle of
support bracket
10-222A
until gearbox mounting contacts left longitudinal member.
Position
engine and gearbox jack
V.A.G 1383/A
with
universal support
V.A.G 1359/2
under final drive and exert slight counter pressure.
Screw in new hexagon bolts
arrows
for left assembly mounting and tighten them to specified torque.
Caution
Do not remove support bracket 10-222/A until all bolts of left engine/gearbox mounting have been tightened to specified torque and turned an additional angle.
Push right drive shaft
A
onto gearbox stub shaft, and install rear torque reaction support
arrows
Running gear, axles, steering
Rep. gr.
40
Removing and installing drive shafts
.
Press left drive shaft onto gearbox stub shaft
Running gear, axles, steering
Rep. gr.
40
Repairing drive shafts; Removing and installing drive shafts
.
Install subframe
Running gear, axles, steering
Rep. gr.
40
Removing and installing subframe
.
Install exhaust system to subframe
Rep. gr.
26
Exhaust system
.
Push on blade connectors
1
and
2
of both gearbox wiring harnesses.
Remove plugs from gearbox and ATF lines.
Renew O-rings of ATF lines.
Moisten new O-rings with ATF.
Ensure that O-rings are seated correctly so that they do not slip from their seats when ATF lines are inserted.
Insert ATF lines completely to stop in gearbox by hand.
Do not tighten nuts until ATF lines have been inserted completely.
Install noise insulation for left and right drive shafts on wheel housing.
Remove
support bracket
10-222A
with
adapter
10-222A/3
,
adapter
10-222A/16
and
adapter
10-222A/23
.
Install dust caps for suspension struts.
Remove coolant hose from connector of ABS control unit, and swivel it downwards.
Fit connector
3
of ABS control unit, and lock connection.
Hook fuel hoses
1
into the retainer on battery housing and into bracket
2
.
Tighten bolts
2
for support bracket of selector lever cable.
Lubricate ball socket of selector lever cable with
polycarbamide grease
G 052 142 A2
.
By hand, press selector lever cable onto lever/selector shaft.
Adjust selector lever cable
Chapter
.
Install left and right plenum chamber bulkhead panels on plenum chamber
General body repairs, interior
Rep. gr.
50
Assembly overview – plenum chamber bulkhead
.
Install plenum chamber cover
General body repairs, exterior
Rep. gr.
64
Bonded windows; Removing and installing plenum chamber cover
.
Install noise insulation on plenum chamber at front.
Install coolant expansion tank
Rep. gr.
19
Cooling system/coolant
.
Connect battery.
Follow procedure after connecting battery
Electrical system
Rep. gr.
27
Battery; Disconnecting and connecting battery
.
Install outer lock carrier covers above headlights and engine compartment cover.
Install wheels
Running gear, axles, steering
Rep. gr.
44
Torque settings for wheel bolts
.
Check ATF level and top up ATF
Chapter
.
Install noise insulation below engine/gearbox.
Note
Carry out a road test after completing repairs.
Specified torques
Gearbox to engine:
A
= dowel sleeves for centring
Bolt
Installation position according to clock
Nm
M12 x 60
12:30 o'clock
80
M12 x 60
Remark
1:30 o'clock
80
M12 x 60
3.00 o'clock
80
M12 x 60
4.00 o'clock
45
M10 x 55
4:30 o'clock
45
M10 x 55
6.00 o'clock
45
M10 x 55
8.00 o'clock
45
M12 x 100
10.00 o'clock
80
This bolt is accessible only after starter has been removed.
Specified torques
Component
Specified torque
Torque converter to drive plate
57 Nm
Bolt for support bracket of selector lever cable
23 Nm
Nuts for ATF lines to gearbox
8 Nm
Assembly mountings
Renew bolts.
Specified torques
Component
Specified torque
Bolts
arrows A
50 Nm +90°
Bolts
arrows B
50 Nm +90°