Note: Description is based on 2.0L AWD models. The DSG is removed downwards with the corner gear, separate from the engine.
1. Set the selector lever to position "R".
2. Disconnect the negative cable from the battery.
3. Remove the engine top cover and air cleaner (see chapter 4).
4. Remove the battery and its holder (see chapter 5).
5. Remove a fairing of a windscreen.
6. Release the latch (1 in illustration 13.9) and lift it up. Then lift up the latch (3). Release the selector cable (2) away from the axis of the selector mechanism in the direction of the arrow and place it on top.
Note: Re-install clamps (1 and 3) not allowed. Do not bend the cable and do not squeeze it out of the support back (the cable is removed from the holder when the selector mechanism is removed).
7. If the lock washers cannot be removed without damaging the cable, two bolts can be removed (1 per resist. illustrations) and remove the support (2) cable.
15.7 Fixing the rope support
8. Disconnect the wire (1 in Illustration 5.24 of Chapter 2) from the starter solenoid valve, disconnect the connector (2) and remove ground wire (3) from the console. Discharge yourself from electrostatic charge and disconnect the connector (4), by turning its lock. Loosen the starter mounting bolts and remove it (see chapter 5). Disconnect all engine/transmission wiring connectors accessible from above.
15.8 Starter and DSG connectors
9. Remove one bolt (And on the opposite illustrations) DSG mounts located in the opening under the starter, using the XZN14 head (Т10061).
15.9 DSG mounting bolt accessible through starter opening
10. Lay a lint-free cloth over the DSG and the DSG fluid cooler to catch the escaping coolant. Mark the coolant hoses in relation to the radiator (so as not to confuse during installation), pinch them with clamps MP7-602. and disconnect the hoses from the DSG fluid cooler (see illustration 14.15). Seal the radiator connections.
11. Give nuts (2 in illustration 14.3) bracket (1) and remove the bracket from the studs on the pallet at the front of the DSG.
12. Remove the filling pieces from the upper edges of both wings. If present, remove the connections located in the area of the engine lifting lug. Screw the T10346 bracket into the back of the three holes in the battery holder, using the M6 bolt or one of the battery holder mounting bolts (see illustration 5.11 Chapter 6). Install supports MP9-200 (№10-222A) behind the hood pillar so that their heel is positioned as illustrated (see callout) - behind the bolt (1) and on the side of the bolt (2). Hook the support spindles to bracket T10346 and to the front left engine lifting eye. Slightly unload the supports of the power unit without lifting it from the supports.
13. Loosen the hub bolts and front wheel bolts, raise the vehicle and remove the front wheels.
14. Remove the soundproofing under the engine compartment and the lockers of the front wheel arches (see chapter 11).
15. Loosen clamps (1 per resist. illustrations) and remove the left charge air hose (2).
15.15 Left charge air hose clamps
16. Pull out the clamps and remove the right charge air hose (see resist. illustration).
15.16 Right charge air hose
17. Remove the casing with fans from the radiator of the engine cooling system (see chapter 3).
18. If available, remove the bolts (arrows in Illustration 21.10 of Chapter 1) and remove the protective plate (A) under DSG.
19. Separate the exhaust system on a double clamp and remove the exhaust system bracket from the subframe. Tie up the exhaust pipe. Do not bend the flexible section more than 10°.
20. Mark the position of the cardan shaft with the flexible disk relative to the output flange of the angular transmission, and then fasten the propeller shaft to the output flange of the angular transmission (see illustration 5.19 Chapter 6).
21. Remove the oscillating support from the DSG by removing the bolts (B and C in Figure 5.20 of Chapter 6).
Note: The swing arm is removed together with the subframe.
22. After removing the oscillating support, the power unit tilts forward slightly, so be careful not to damage the gasket (see illustration 5.21 of chapter 6) in the driveshaft flange. Press the power unit forward, pull the driveshaft off the angle drive flange and tie up the shaft on the body.
23. Disconnect the engine oil temperature and level sensor connector on the underside of the engine oil pan (see chapter 2).
24. Fix the subframe and remove it together with the swing arm, anti-roll bar, consoles, steering gear and suspension arms.
25. On diesel models with a particulate filter, remove it together with the bracket.
26. If available, remove the bolts (1 in Illustration 4.40 of Chapter 1) and remove the heat shield (A) right drive shaft. Disconnect the left and right drive shafts (WITH) from the DSG flange shafts and tie the drive shafts to the suspension struts as high as possible. Do not damage the protective coating of the shafts.
27. Give nuts (1 per resist. illustrations) supports (A) DSG on corner gear. Loosen nuts (2 and 3) DSG mounts on the engine.
15.27 Fixing the DSG support
Note: Fully retract the nut (3) will not succeed, because it will rest against the right drive shaft; The DSG support can only be removed after the DSG has been removed from the engine.
28. Remove the bolts (1 and 2 in Illustration 5.28b of Chapter 2), evenly lower the power unit on the spindles of the MP9-200 (№10-222A) 4 turns and remove the console (A) supports.
29. Evenly lower/raise the power unit on the MP9-200 spindles (№10-222A) so that the distance (and on the opposite illustrations) was 100-110 mm.
15.29 DSG lowering distance
30. Mount the #3282 base plate with adapters to the DSG as indicated on the resist. illustration, and fasten the DSG straps to this plate. Place a transmission jack under the DSG and secure the base plate to it.
15.30 Devices for holding the DSG on the jack
31. Turn out a bolt of fastening of DSG to the engine near angular transfer (arrow to illustration 5.28 Chapter 6).
32. Remove the remaining bolts (6-9 on resist. illustrations), slide the DSG off the mounting sleeves (A) and pull it away from the engine by about 30 mm.
15.32 Centering sleeves (A) and DSG mounting bolts
A Centering sleeves
1, 2, 4 Bolts M12x55, 80 Nm
3 Bolt M 10x45 fastening the starter to the DSG, 40 Nm
5 Bolt M 10x40 fastening the starter to the DSG, 40 Nm
6 Bolt M 12x65, 80 Nm
7-9 Bolts M 10x50, 40 Nm
10 Bolt M 12x65, inserted from the engine side, 80 Nm
33. Give the final nuts (2 and 3 in illustration 15.27) securing the DSG mount to the engine and remove the mount. Gently tilt the DSG towards the left side member, changing its position on the #3282 mount spindles. Lower the DSG from the engine compartment by moving the selector cable out of its holder. Remove the DSG, keeping an eye on its connecting lines.
34. Check and, if necessary, replace the needle bearing in the crankshaft. Lightly grease the needle bearing and the end of the input shaft (not splines) high temperature grease G052 133A2.
35. Make sure that the centering sleeves are present (And in the illustration 15.32).
36. Installation is carried out in the reverse order. The tightening forces of the DSG fasteners to the engine are shown in illustration 15.32. Tighten the bolts of the DSG support console with a force of 60 Nm, and then tighten by an angle of 90°; bolts securing the DSG support to the console, tighten with a force of 40 Nm, and then tighten by an angle of 90°.