Note: The description is given using the example of the manual transmission "02Q" (aWD models).
Note: When removing, remember the routing of hoses, tubes, electrical wiring, etc., so that you can later lay them in the same way.
1. Disconnect the negative cable from the battery.
2. Remove the air cleaner (see Chapter 4).
3. Remove the battery and its holder (see Chapter 5).
4. Remove the retaining ring (3 in illustration 4.16) selector cable from the selector lever (1) and remove the cable from the pin (arrow). On models with a metal slot selector lever (2), remove the slot selector cable retaining ring (4) and remove the cable from the pin (arrow).
5. On models with a plastic slot selector cable, release the cable lock at the end (see paragraphs 5 of Section 4).
6. Give away the fasteners (see illustration 4.18), remove the cable holder from the manual transmission, set it aside and tie it up. If present, remove the sound insulation under the engine compartment (see Chapter 11).
7. If present, remove the vent tube from the angular transmission (see accompanying illustration).
5.7 Angular transmission breather
8. A line in the form of a tube/hose or a plastic line may be installed between the clutch master cylinder and the bleed nipple. If a plastic line is installed, the plastic return hose (3 on the accompanying illustration) must be removed from the master cylinder and plugged. Do not pinch the plastic hose, as this may damage it. After disconnecting the clutch hydraulic line, do not press the clutch pedal.
5.8 Brake fluid line connections
9. If the line is installed as a tube/hose, pinch the hose (And on the accompanying illustration), going to the master cylinder, with clamp MP7-602 or No.3094, pull out the retainer (arrow) until it stops, disconnect the clutch hydraulic drive line from the slave cylinder/bleed nipple and plug it. After disconnecting the clutch hydraulic drive line, do not press the clutch pedal.
5.9 Clutch hydraulic line connection
10. Disconnect the starter wire from the max (1 on the accompanying illustration), disconnect the connector (2) of the reversing D/W lamps and the starter connectors. Remove the upper transmission/engine connecting bolts and the upper starter bolt.
5.10 Wiring connectors in the starter area
11. Remove the filler pieces from the upper edges of both wings. If present, remove the connections located in the area of the engine lifting eye. Screw the T10346 bracket into the rear of the three holes in the battery holder, using an M6 bolt or one of the battery holder mounting bolts (see accompanying illustration). Install the MP9-200 supports (No. 10-222A) behind the hood pillar so that their heel is positioned in accordance with the illustration (see footnote), behind the bolt (1) and to the side of the bolt (2). Hook the support spindles to the T10346 bracket and to the front left engine lifting eye. Slightly relieve the power unit supports without lifting it from the supports.
5.11 Hanging the power unit
12. Remove the front wheels and sound insulation under the engine compartment.
13. Remove the starter bracket and the starter itself (see Chapter 5).
14. Disconnect the connector (2 on the accompanying illustration) boost pressure sensor "G41", unscrew the bolt (4) and remove the air duct between the intercooler and the intake manifold, slightly lifting the clamps (1 and 3).
5.14 Removing the tube between the intercooler and the intake manifold
15. Disconnect the connector (1 in illustration 15.16 Chapter 2), unscrew the bolts (arrows) and remove the fan casing.
16. Remove all exhaust system supports from the manual transmission and exhaust pipe (see Chapter 4).
17. Disconnect the exhaust system at the clamp and remove the exhaust system bracket from the subframe. Tie up the exhaust pipe.
Note: Do not bend the flexible section of the exhaust pipe more than 10° to avoid damage.
18. If present, remove the drive shaft cover (see accompanying illustration).
5.18 Fastening the drive shaft cover
19. Mark the position of the cardan shaft with the flexible disk relative to the output flange of the angular transmission, and then loosen the fasteners of the cardan shaft to the output flange of the angular transmission (see accompanying illustration).
5.19 Fastening the cardan shaft to the angular gear
20. Remove the rocker support from the manual transmission by unscrewing the bolts (B and C in the accompanying illustration).
5.20 Fastening of the swing support
21. After removing the rocker support from the manual transmission, the power unit tilts slightly forward, so be careful not to damage the gasket (see accompanying illustration) in the flange of the cardan shaft. Push the power unit forward, pull the cardan shaft off the flange of the angular transmission, lift the cardan shaft and tie it to the body.
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5.21 Cardan shaft flange seal
22. Disconnect the engine oil temperature and level sensor connector on the bottom of the engine oil pan (see Chapter 2).
23. Disconnect the front left suspension height sensor connector and remove the nut (2 on the accompanying illustration), unscrew the bolt (1) and remove the sensor.
5.23 Sensor "G78" front suspension height
24. Fix the subframe and remove it together with the console without the steering gear, left arm and anti-roll bar (see Chapter 10).
25. Remove the front drive shafts from the flange shafts (see Chapter 8). Tie the drive shaft to the front suspension spring so that it does not bend at the hinge. Do not damage the shaft coating.
26. On models without a DPF, remove the turbocharger oil line from the engine (And on the accompanying illustration), loosen the fasteners (arrows) and remove the support between the engine and the angular transmission.
5.26 Oil line (A) and angular gear bracket fastener
27. On models with a diesel particulate filter, remove it together with the bracket and unscrew the bolts (1-3 on the accompanying illustration) fastening the support between the engine and the angular transmission.
Note: The support can only be removed after separating the manual transmission from the engine.
5.27 Fastening of the manual transmission holder
28. On models with additional heating it is necessary to remove the angular transmission (1 on the accompanying illustration), as described in Chapter 8. Otherwise, the auxiliary heater tube (2) will be damaged. The engine/transmission connecting bolt (arrow) can only be removed from the cylinder block after removing the tube (2).
5.28 Angle gear on models with additional heater
29. Remove the bolts (arrows in the accompanying illustration) fastening the support (2) of the manual transmission to the console (1).
5.29 Bolts for fastening the manual transmission support to the console
30. Lower the manual transmission on the spindle of the MP9-200 device so that the distance (and in the accompanying illustrations) was approximately 60 mm.
5.30 Size for lowering the manual transmission
31. Remove the bolts (arrows in the accompanying illustration) console mounts (1) and remove it from the manual transmission.
5.31 Console mounting bolts
32. Remove the slot selector lever. On models with a metal lever, (1 on the accompanying illustration) select the groove, remove the retaining ring (arrow) and remove the lever. A description of how to remove the plastic lever is given in Section 4.
5.32 Retaining ring of the metal lever for selecting the groove
33. Remove the gear selector lever from the selector shaft (see Section 4).
34. Remove the lower bolts securing the manual transmission to the engine.
35. Attach support fixture #3282 with plate #3282/33 to the transmission jack (see accompanying illustration). Fix the MP3-419/40 adapter in the threaded hole of the manual transmission, screw bolt No.3282/29 into the mounting hole of the rocking support, and also screw bolt M10x20 (A). Unscrew bolt (C) for fastening the manual transmission.
5.35 Installing the support for removing the manual transmission and the manual transmission mounting bolt (3)
36. On models with additional heating, unscrew the bolt (1 on the accompanying illustration) and carefully press the tube (2) away from the engine in the direction of the arrow.
5.36 Separating the auxiliary heater tube from the engine
37. Remove the small cover (And on the accompanying illustration) flywheel, unscrew the bolt (arrow) securing the manual transmission and press the manual transmission away from the engine (on centering bushings).
5.37 Flywheel cover and manual transmission mounting bolt
38. On models with a diesel particulate filter, remove the support (And on the accompanying illustration) between the engine and the angular transmission.
5.38 Support between the engine and the manual transmission
39. Turn the manual transmission through the spindle (See accompanying illustrations) support #3282 in the differential area upwards and position the manual transmission through the spindle (2) of support #3282 at an angle to the left. Then remove the manual transmission and angular gear assembly from the flywheel, making sure that it does not touch the side member (arrow). Carefully lower the manual transmission, watching its connecting lines.
5.39 Removing the manual transmission
40. Clean the input shaft splines and lightly lubricate with G000 100 grease. The clutch disc should move easily on the input shaft.
41. Make sure that the transmission centering bushings are correctly seated on the engine. Without centering bushings, there may be difficulties with gear shifting, clutch problems, and transmission noise (from disengaged gears). Also make sure that the intermediate plate is positioned correctly on the engine.
42. Installation is carried out in the reverse order. Use new self-locking bolts and nuts. The tightening forces of the bolts securing the manual transmission to the engine, as well as the fasteners of the supports, are specified in Sections "Removing and installing the engine" Chapter 2.