Section A - Transmission Removal

Obtain the anti-theft radio security code

- Switch off all electrical consumers

- Move gear selector into park "P" position

- Switch ignition off and remove ignition key

- Open rear hatch and fold luggage compartment floor panel forward

- Disconnect the negative (-) terminal (GND) -arrow- from the battery

NOTE:
Battery is in the left rear corner of the vehicle

WARNING:
- THE COOLING SYSTEM IS UNDER PRESSURE WHEN THE ENGINE IS WARM. IF NECESSARY, REDUCE PRESSURE BEFORE REPAIR

- COVER CAP OF EXPANSION TANK WITH A RAG AND OPEN IT CAREFULLY, AS HOT STEAM, E.G., HOT COOLANT, MAY ESCAPE WHEN OPENING





- Open hood and slowly open cap from the coolant expansion tank to relieve the pressure in the system

- Remove clips -arrow A- from left side lock carrier cover -1- and remove cover

- Remove screws -arrow B- from fuse box cover -2- and remove cover

- Remove clips from right side lock carrier cover and remove cover





NOTE:
To remove the lock carrier clips, press pin -2- approximately 4 mm only (do not press completely through), then remove clip -1-





- Loosen clamp -2- and remove air hose from the throttle body housing

- Disconnect the electrical connector -3- from the Mass Airflow Sensor (MAF)

- Remove bolts -1- and -4-

- Move wiring harness -arrow- aside

- Remove the air cleaner housing with MAF and air hose





- Unclip protective cover -1- for wiring

- Raise fuse box carrier lid -arrows-





- Depress the retainers with a screwdriver -arrow- and remove the fuse box from the carrier





- Remove bolts -arrows-

- Remove fuse box carrier

- Touch vehicle ground with your hand (without gloves) to discharge any static electricity





- Disconnect electrical connectors -3- and -4-

- Remove the nut at the starter solenoid terminal B+ -2- and remove the connector eyelet from the terminal

- Remove connector -1- from the wire guide

- Unclip guide from wires

- Remove wire guide

CAUTION: DO NOT LOOSEN OR REMOVE GROUND (GND) CONNECTION -5-

- Remove the nut securing the power steering pressure line bracket from the upper starter bolt and swivel bracket upwards

- Remove the upper starter bolt

- Remove bolt on clamp securing power steering pressure line next to transmission oil cooler





- Slide circlip -A- upward and remove it in direction of arrow

- Remove selector lever cable off selector shaft lever in direction of arrow and place on top

NOTE:
DO NOT loosen bolt -B-

- Remove torx bolts -1-

CAUTION:
DO NOT KINK SELECTOR LEVER CABLE





- Clamp off transmission oil cooler hoses using hose clamps -3094- and disconnect at transmission oil cooler -A-

- Seal off transmission oil cooler with clean plugs





- Remove engine/transmission connecting bolt -1-





- Assemble support bracket 10-222 A together with brackets 10-222 A/1 and 10-222 A/3

- Position support bracket on wheel housing flange

- If there are hoses and cable connections in area of engine lifting eye for support bracket 10-222 A, move them aside

- On right side, attach hook of spindle to engine lifting eye with a shackle 10-222 A/12 -1-

- Take up the weight of engine/transmission assembly via spindles on the support bracket

- Raise vehicle on hoist





- Unclip clips -1-

- Remove screws -2- and -3-

- Use tool T 10035 and remove screws -4-

- Remove center sound insulation panel and set aside





- Remove front wheels

- If the vehicle is equipped with automatic headlight control, disconnect connector -9- from the sensor -1-

- Remove bolt -6- and disconnect linkage arm bracket -7- from the lower control arm -5-

- Remove nuts -2- and remove sensor with mounting bracket





- Remove fasteners -arrows- and left side sound insulation panel





- Remove bolts -1- and -2- and remove coolant hose bracket -A-

- Remove clamp on the power steering line





- Remove nut -1- and other nut securing the secondary air pump air filter holding bracket -A-

- Disconnect air hose from the air filter and remove air filter





- Remove lower starter bolt -3- with bracket for cable guard

- Remove nut -2- and remove the ground connector eyelet

NOTE:
To see bolt -1- nut -2- and bolt -3-, look upward through opening made when the air filter for the secondary air pump was removed

- Remove bolt -1- securing transmission to the engine





- If installed, remove torx bolts -arrows- and protective plate -A- from the bottom of the transmission





- Unscrew and remove upper nut -arrow- from both front ball joints





- Use ball joint puller 3287 A and press out ball joints on the right and left control arms

- Remove ball joint puller





- Insert the 3004 hooks into openings in the underbody; with a small piece of chain support exhaust system

NOTE:
Plugs may need to be removed in the underbody before inserting hooks

CAUTION:
THE FLEXIBLE PIPE CONNECTION (DE-COUPLING ELEMENT) OF THE EXHAUST SYSTEM MUST NOT BE BENT MORE THAN 10°; OTHERWISE, IT CAN BE DAMAGED





- Loosen nuts -arrows- and disconnect exhaust system at clamp

- Slide clamp rearward onto exhaust pipe





- Remove allen head nuts -arrows- and remove the axle shaft heat shield from the bevel box

- Remove bolts securing right axle to flange on the bevel box

- Remove bolts securing left axle to flange on the transmission

- Lift axle shaft (right side) up and secure with wire





CAUTION:
LOOSENING BOLTS FOR THE PENDULUM SUPPORT TO SUB-FRAME CAUSES THE ENGINE/TRANSMISSION ASSEMBLY TO SWING FORWARD SLIGHTLY

- Push engine/transmission assembly forward slightly and then pull drive shaft off bevel box

- Place drive shaft above bevel box and secure it to prevent it falling





- Secure the tie rods to the suspension strut just in front of the inner rubber boot using tensioning strap T 10038, to prevent the steering column from sliding off the splines of the steering gear





- Remove nuts securing the right and left coupling rods to the stabilizer bar





- Remove eight bolts -1- with locking washer -2- and remove reinforcement -3-





- Remove bolts -1- securing steering gear

- Remove nut above bolt -2- securing brake booster vacuum pump bracket

- Remove bolt -2- securing steering gear

- Remove bolt securing bracket for brake booster vacuum pump located above the left rear area of the sub-frame

- Position V.A.G. 1383 A with universal mount 1359/2 under sub-frame

- Remove bolts -3- and -4- for sub-frame





- Carefully pry off the sub-frame for steering gear using a pry bar

NOTE: Do not make contact with the side noise insulation and bracket for the power steering hose on the left side when lowering

- Carefully lower the sub-frame and set aside

- Move left drive shaft clear toward rear and secure with wire





- Mark position -arrows- of drive shaft with flexible coupling in relation to bevel box flange





- Remove bolts -arrows- and remove drive shaft with flexible coupling from bevel box flange





- Move drive shaft horizontally to rear as far as possible

CAUTION:
WHEN REMOVING THE TRANSMISSION, MAKE SURE THE SEAL -ARROW- IN THE DRIVE SHAFT FLANGE IS NOT DAMAGED. IF THE SEAL IS DAMAGED, THE DRIVE SHAFT MUST BE REPLACED.





- Remove bolts -1- and -2- and remove bracket for bevel box

- Lower vehicle on hoist





- From above in the engine compartment remove starter in an upward direction

- Remove bolts -2- then bolts -1-

- Remove transmission mounting bracket -A-





- Carefully lower engine/transmission assembly using spindles 100 to 110 mm (3.9 to 4.3 inches) see next illustration for location of measurement





- Distance -a- = 100 to 110 mm (3.9 to 4.3 inches) measured between transmission housing and mounting

- To remove the direct shift transmission 02E the transmission support 3282 is set up together with the adjustment plate 3282/42

- Align arms of transmission support according to holes in adjustment plate

- Bolt support elements as illustrated to adjustment plate 3282/42

- Place transmission jack under vehicle at arrow symbol on adjustment plate points in direction of travel/to front of vehicle

- Align adjustment plate parallel with transmission





- Secure support element to transmission using bolt -1-

- Screw support element 3282/29 into transmission

- Insert support element -2- into transmission; secure by tightening nut





- Support transmission by lifting transmission jack from below

- Remove bolts -5-, -6-, -7-, -8-, -9- and -10- securing transmission to the engine

NOTE:
The bevel box is not shown in this illustration. It obstructs the view of bolt -10-

- Pry transmission off dowel sleeves

- Pull transmission off engine first from bevel box side and then from front side

- Carefully lower transmission, making sure wires are not trapped

- When lowering, change position of transmission by using the spindles on transmission support 3282.

- Proceed to Section B