Removing gearbox, 2.0 l - 155 kW petrol engine: VW Jetta VI

🧭 Before you start

Fits: VW Jetta VI (16, 2010–2018)

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: T40091/1, locking pin

Don't miss

• On a warm engine, the cooling system is under high pressure.Before pulling off the coolant hoses, cover the filler cap on the coolant expansion tank with a cloth, and open it carefully.
• Take up weight of engine/gearbox assembly on spindles; do not lift.
• Raise vehicle. All 4 supports of lifting platform must be at same height.
• If the (subframe) is not located, it will be necessary to perform a wheel alignment later.
• Put left drive shaft to rear and secure (do not damage surface protection when doing this).

🔩 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.

📋 Procedure

1. Move selector lever to position »P«.
2. First check whether a coded radio is fitted. If so, obtain anti-theft code.
3. Disconnect battery earth strap Electrical system27Battery; Disconnecting and connecting battery.
4. Remove engine cover panel 10Engine cover panel; Removing and installing engine cover panel.
5. Remove complete air filter housing 24Air filter; Removing and installing air filter housing.

6. Remove battery and battery tray Electrical system27Battery; Removing and installing battery.
7. Remove selector lever cable from gearbox (arrows). [Note: Use pliers to remove the securing clip on the cable support bracket. Do not use a sharp-edged lever. The selector lever cable could otherwise be damaged.If necessary, remove cable support bracket (2) with selector lever cable from gearbox. To do this, unscrew bolts (1) and remove securing clip (3).The bolts (1) and the securing clips must be renewed.Specified torque for bolts (1): 20 Nm + turn 90° further.]
8. ⚠ Risk of damage to selector lever cable.Guide out selector lever cable from cable support bracket when lowering gearbox.Do not bend or kink selector lever cable. — Lay lint-free cloths on gear oil cooler and gearbox to catch escaping coolant. [Note: On a warm engine, the cooling system is under high pressure.Before pulling off the coolant hoses, cover the filler cap on the coolant expansion tank with a cloth, and open it carefully.]
9. Clamp off coolant hoses using hose clamps3093 or 3094 and remove hoses from gear oil cooler.
10. Seal union of gear oil cooler using suitable plugs, for example those from engine bung setVAS 6122.
11. Remove starter (A)Electrical system27Starter; Removing and installing starter.
12. ⚠ Risk of damaging mechatronic unit for dual gearbox J743 beyond repair through static discharge.Do not touch the contacts in the connector of the mechatronic unit for dual clutch J743 by hand. — To become electrostatically discharged, touch an earthed object by hand (without gloves) .
13. Release rotary locking mechanism of connector (1) for mechatronic unit by turning in »anti-clockwise direction«, and pull off connector.
14. Remove electrical wiring and retainer from gearbox cover at front (arrows) (2 x M6 nuts)
15. Tie up wiring in area of gearbox cover.
16. Remove all upper connecting bolts between engine and gearbox.
17. Remove plenum chamber cover General body repairs, exterior50Plenum chamber bulkhead; Assembly overview - plenum chamber cover.
18. Unscrew bolts (arrows) for lock carrier bracket on left and right.
19. Unscrew lower supports from adapters10 - 222 A /28, and replace them with supports 10 - 222 A /28-2.
20. Unscrew bolts (arrows) for attaching engine support on lock carrier from adapter10-222 A /28-2.
21. Fit adapter10 - 222 A /28 and tighten the bolts (arrows) to 8 Nm. — 8 Nm (5.9 lb-ft)
22. ⚠ A 2nd mechanic is needed to place support bracket on the vehicle in order to prevent the support bracket from tipping. — If there are hose and cable connections in area of engine support eye for support bracket10 - 222 A, remove these now.
23. First, push swivel joints(item 2) onto square tube of support bracket10 - 222 A.
24. Fit support bracket10 - 222 A on suspension turrets with the aid of a second mechanic to prevent it from tipping.
25. T40091/1 Push (item 5) on left and right from front through 10 - 222 A /28(item 6), and fit swivel joints T40093/4(item 4) on each side.
26. Push hook rail T40091/2(item 7) with support T40093/5(item 8) into swivel joints T40093/4(item 4).
27. Insert locking pin in hook rail T40091/2(item 7) and secure with split pins.
28. Tighten all threaded connections of support bracket by hand. When doing this, adjust support bracket via adapters10 - 222 A /28 so it is parallel in height.
29. Take up weight of engine/gearbox assembly on spindles; do not lift.
30. Loosen wheel bolts on front left and front right.
31. Raise vehicle. All 4 supports of lifting platform must be at same height.
32. Remove front wheels.
33. Remove noise insulation General body repairs, exterior66Noise insulation; Assembly overview - noise insulation.
34. Remove front left wheel housing liner General body repairs, exterior66Wheel housing liner; Assembly overview - front wheel housing liner.
35. ⚠ Risk of damage to decoupling element.Do not bend decoupling element more than 10°.Install decoupling element so that it is not under tension.Take care not to damage wire mesh on decoupling element. — Separate exhaust system at clamp, and remove exhaust system bracket from subframe (arrows)26Exhaust pipes/silencers; Assembly overview - silencer.
36. Tie up front exhaust pipe.
37. Unbolt pendulum support from gearbox by undoing bolts (11).
38. Fix subframe in position prior to removal Running gear, axles, steering40Subframe; Fixing subframe in position. [Note: If the (subframe) is not located, it will be necessary to perform a wheel alignment later.]
39. Remove subframe with steering rack Running gear, axles, steering40Subframe; Removing and installing subframe with steering rack.
40. Remove heat shield above right drive shaft (arrows).
41. Remove drive shafts from gearbox Running gear, axles, steering40Removing and installing drive shaft.
42. Raise right drive shaft as high as possible and secure.
43. Put left drive shaft to rear and secure (do not damage surface protection when doing this).
44. A small cover plate may be located above the right drive shaft flange on the intermediate plate for engine and gearbox. If fitted, remove this cover plate (A).
45. Remove all bolts (1) and (2) for gearbox bracket (A).
46. Then, lower engine and gearbox slightly using spindle of support bracket10 - 222 A so that gearbox bracket can be removed.
47. Remove gearbox bracket (arrow).
48. Align arms of gearbox support according to holes in adjustment plate3282/42 A.
49. Screw in support elements as illustrated on adjustment plate3282/42 A.
50. Position engine and gearbox jackV.A.G 1383 A under vehicle.
51. Align gearbox support3282 parallel to gearbox.
52. Screw pin3282/29 into gearbox.
53. Secure both other support elements on gearbox as shown in illustration. [Note: Rather than as shown in illustration on adjustment plate, front support element is bolted onto gearbox as shown (arrow).Illustration shows dual clutch gearbox 02E "“all-wheel drive”". Support elements are identical on "“front-wheel drive”".]
54. Raise gearbox and engine supportV.A.G 1383 A from below to support gearbox.
55. Remove remaining engine/gearbox connecting bolts.
56. Press gearbox off engine, »observing selector lever cable« and lower gearbox. [Note: Be careful of all lines when lowering gearbox.]

Other VW procedures

• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures
• VW EOS 2.0 FSi BVY/BVZ gearbox removal & installation
• VW Polo4 1.0 ARA timing belt replacement
• VW T5 1.9TDi, 01, 2006 timing belt replacement
• VW T5 2.0 AXA timing belt replacement
• VW Golf6, Golf Plus6 1.6 timing belt replacement