Contents: Removal ⬇ Installation ⬇
Removal
Note.
- Necessary special devices, control and measuring instruments, as well as auxiliary means:
- Gearbox mounting device (3282).
- Mounting plate (3282/31).
- Device for removing and installing the engine and gearbox (for example "VA G 1383/A").
- Transport device (MRZ-478(3336)).
- Fixing suspension device (MP9-200 (10-222A)).
- Tip (MP9-200/3 (10-222A/3)).
- Hook for MP9-200 and T30099 (MP9-200/10 (10-222A/10)).
- Grease (G 000 100).
1. Remove the upper decorative engine cover.
Note.
- All wire connections that were loosened or disconnected during removal must be re-fastened in the same place during reinstallation.
- After disconnecting and then connecting the wire connecting the battery terminal to the ground (body) of the vehicle, some additional work must be performed.
2. With the ignition off, disconnect the wire connecting the battery terminal to the vehicle ground (body).
3. Remove the air filter (for more details, see the relevant section in the chapter Intake and exhaust system).
4. Remove the battery and battery holder (for more details, see the relevant section in the chapter Engine electrical equipment).
5. Remove the retaining ring (shooter 1) cable drive of the gear shift from the gear shift lever (A), as shown in the figure below.
6. Remove the gear shift cable from the journal.
Metal selector lever
7. Remove the retaining ring (arrow 2) of the cable for the selective shift control device from the selector lever guide (B), as shown in the figure below.
8. Remove the cable drive for the pre-selective gear shift control device from the journal.
9. After removing the retaining ring (arrow 3) from the selector lever (B), remove the selector lever as shown in the figure below.
Note: Retaining rings must always be replaced.
Plastic selector lever
Note: To prevent damage to the cable drive for the selective shift control device, it is necessary to separate the flexible shaft locking device (bowden cables) from the cable drive for the selective gear shift control device before proceeding with extraction.
10. After tightening the locking device forward as far as it will go in the direction (arrow 1), then secure it by turning it to the left in the direction (arrow 2), as shown in the figure below.
11. The preselector guide lever should be removed together with the flexible shaft locking device (bowden cables).
Continued for all cars
12. Remove the gear shift lever (A) by unscrewing the nut (arrow 4), as shown in the figure below.
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13. Remove the flexible roller counter support (bowden cables) (arrows) as shown in the figure below.
14. Then tie the gear shift cable and the cable for the pre-selective shift control device on top.
15. Remove the pipe and hose line (A) from the holder (B) on the gearbox (if the holder is installed), as shown in the figure below.
16. After removing the clutch release drive slave cylinder (arrows), put it aside and secure it with wire. Do not disconnect the wire.
Note: Do not depress the clutch pedal.
Cars with gasoline engines
17. Disconnect the wiring harness connector (arrow) from the speedometer sensor "G22" (if installed), as shown in the figure below.
Cars with diesel engines
18. Disconnect the wiring harness connector (arrow) from the speedometer sensor "G22" (if installed), as shown in the figure below.
Continued for all cars
19. Remove the ground wire (housing) from the bolt connecting the engine and gearbox (1) (some types of motor have no wire connected), as shown in the figure below.
20. Disconnect the wiring harness connector (2) shown in the figure below.
21. Remove the starter wire to ground (housing) (3) as shown in the figure below.
22. Put all electrical wires aside.
23. Unscrew the upper bolts connecting the engine and gearbox.
24. Unscrew the upper starter mounting screw.
25. Hang up the power unit assembly.
To do this:
Remove the windshield wiper arms.
Remove the cap of the expansion tank of the engine cooling system (for more details, see the relevant section in the Cooling System chapter).
Remove the plastic covers from the upper shock absorber strut mounts in the engine compartment.
Install a special device for hanging the power unit (T30099) together with a beam (T30099/1) and a grip for the device MP9-200 and T30099 MP-200/10.
Note: Secure the special device for hanging the power unit.
26. Using the lead screw (spindle), apply slight pre-stress to the engine-gearbox unit.
27. Remove the mounting screws (arrows) from the gearbox bearing as shown in the figure below.
28. After removing the left front wheel, lift the car.
29. Remove the lower engine protective cover.
30. Remove the wheel arch (wing) liner of the left front wheel (for more details, see the corresponding section in the chapter Body).
31. Disconnect the wiring harness connector (1) from the reverse gear switch as shown in the figure below.
32. Unscrew the mounting bolts and remove (arrow) the mounting bracket (2) from the gearbox, put it aside together with the wires, as shown in the figure below.
33. Remove the starter assembly (for more details, see the relevant section in the chapter Engine electrical equipment).
34. Remove the front part of the exhaust pipe (for more details, see the relevant section in the chapter Intake and exhaust system).
35. Unscrew the mounting bolts and remove the heat-protective sheet (arrows) (if it is installed) for the inner constant velocity joint of the right drive shaft, as shown in the figure below.
36. Remove the drive shafts with flanges; turn the steering wheel all the way to the left.
37. Unscrew the mounting bolt and remove (if installed) small protective sheet (A) for the flywheel behind the right flange shaft (arrow), as shown in the figure below.
38. Loosen the nuts (arrows) securing the lower arm of the front suspension to the ball joint, as shown in the figure below.
39. Unscrew the mounting bolts and remove the rocking support (arrows), shown in the figure below.
40. Disconnect the wiring harness connector (2) shown in the figure below.
Note: Unscrew the air conditioner pipe holder (if available in the equipment) from the fan bracket.
41. Unscrew the fastening screws (arrows), remove the fan holder downwards (the new models no longer have screws, and the fan holder is simply pushed into the clamping clamps), as shown in the figure below.
42. After releasing the fan shroud on the retainer, using a suitable tool, remove it as shown in the figure below.
43. Remove the mounting bolts shown by arrows in the figure below. Then remove the mounting bracket (A) from the gearbox as shown in the figure below. Remove the mounting bolts (arrows) of the gearbox bracket as follows.
Lower the engine-gearbox unit through the lead screw to such an extent that access to the gearbox bracket mounting bolts (A) is available from the wheel arch of the left wheel.
Note: When lowering the engine-gearbox assembly, ensure that the gearbox does not touch the front suspension subframe.
44. Unscrew the bolt connecting the engine and gearbox above the right shaft with the flange.
45. Install the gearbox mounting fixture (3282) into the engine and gearbox removal and installation device, e.g (VAG 1383/A).
46. Assemble the device for removing and installing the engine and gearbox using the technology below, with a device for fastening the gearbox (3282), a mounting plate (3282/31) for the "02T" gearbox and fastening elements:
Place the mounting plate (3282/31) on the gearbox mounting fixture (3282) (the mounting plate can only be installed in one single position).
Adjust the position of the gearbox mounting device arms to the holes in the mounting plate.
Screw in the fastening elements (A) according to the marks on the mounting plate, as shown in the figure below.
47. Place the engine and gearbox removal and installation device under the vehicle with the arrow symbol (B) on the installation plate pointing in the direction of vehicle travel, as shown in the figure below.
48. Align the mounting plate parallel to the gearbox and secure its retaining clips.
49. Unscrew the lower mounting bolts connecting the engine and gearbox.
50. Having pressed the gearbox away from the engine, move it towards the front suspension subframe assembly.
For cars with 1.4/51 kW engine
51. While lowering the gearbox, remove the inserted spacer (arrow) shown in the figure below.
Continued for all cars
52. Push the engine towards the radiator. This operation should be performed by a second mechanic.
53. Carefully lower the gearbox assembly.
54. During lowering, the position of the gearbox should be changed using the lead screws of the gearbox mounting device (3282).
55. Connect the transport device (MRZ-478 (3336)) to the clutch housing, as shown in the figure below.
56. Adjust the console on the sliding part using the clamp. Number of visible holes (arrow) = 5.
57. Lift the gearbox using a shop crane and a transport device (MRZ-478 (3336)).
58. Place the gearbox on a transport pallet.
Installation
Note: Before installation, unscrew the threaded plug to check the oil level and, if necessary, add transmission oil.
1. Installation is performed in the reverse order of removal. Ensure that the unit is installed in the vehicle without pre-tensioning.
2. The retaining rings (1), (2) and (3) shown in the figure below should be replaced after each removal.
3. After installation, check the oil level in the gearbox.
Note.
- After cleaning the splines on the drive shaft, lightly lubricate them with consistent grease (G 000 100).
- The clutch disc on the input shaft must be free to move back and forth.
- When replacing the gearbox, ensure that the intermediate sheet is correctly installed between the engine and the gearbox.
- Check the presence of centering bushings in the cylinder block for centering the gearbox; if necessary, insert them.
- Assemble the exhaust system in such a way that it is free of internal stress.
- Installing the starter and wires.
- If necessary, adjust the gear shift drive.
- Add coolant.
- After disconnecting and then connecting the wire connecting the battery terminal to the vehicle ground (body), some additional work must be performed.
- Check the geometry of the vehicle.