Transmission, Removing And Installing: Removing

Special tools and workshop equipment required 

• Engine Support Bridge :10-222A 
• Transmission Support :3282 
• Transmission Support Elements (determine when mounting the Adjustment Plate on the Transmission Support)
• Engine and Gearbox Jack :VAS6931 
• Tensioning Strap :T10038 
• Engine Support - Basic Set :T40091 
• Engine Support - Supplement Kit :T40093A 
• Transmission Support - Mounting Plate 31 :3282/31 
• Transmission Support - Pins 45 :3282/45 
• Socket - Xzn 14 :T10061 
• Grease for Clutch Disc Shaft Splines

Mandatory Replacement Parts

• Lock washers - Selector lever cables
• Bolts - Transmission mount
• Bolts - Transmission support

-- Determine whether a coded radio is installed. If so, obtain the anti-theft code.

Disconnect the battery ground cable. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the complete air filter housing. Refer to AIR FILTER (CNLA & CRJA) , or AIR FILTER (CZCA, CZDA & CZTA) , or AIR FILTER (CBPA & CKJA) , or AIR FILTER (CPLA, CPPA, CPKA & CPRA) .

-- Remove the battery and the battery tray. Refer to BATTERY TRAY, REMOVING AND INSTALLING .

-- Remove the shift cable lock washer -arrow 1- from the selector lever -B-.

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-- Remove the shift cable from the pins.

-- Remove the cable retainer from the selector cable. Refer to Figure.

-- Remove the relay lever -A- and the cable retainer.

-- Remove the nut -arrow 2- and remove the transmission shift lever -B-.

-- Remove the cable mounting bracket from the transmission -arrows-.

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-- Tie up the shift cable and the selector cable.

-- Disconnect the line between the clutch master and clutch slave cylinders -A- from the bracket -B-.

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-- Remove the clutch slave cylinder -B arrows- lay aside and secure with wire. Do not open the line system.

-- Remove the ground cable from the bolt on the top of the starter -1-.

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-- Disconnect the connector -2- and remove the wire from the starter -3-.

-- Remove the upper bolt from the starter.

-- Remove the upper engine/transmission bolts.

-- Transmission on vehicles with Start/Stop System: disconnect the connector -arrow- from the Transmission Neutral Position Sensor -G701-.

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-- Remove the plenum chamber cover. Refer to BULKHEAD .

-- Remove the bolts -arrows- for the left and right lock carrier brackets.

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-- Remove the lower mounts on the :10-222A/28  and replace with the :10-222A/28-2  .

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-- Remove the bolts -arrows- for securing the engine support bridge on the lock carrier from the :10-222A/28-2  .

• Use the bolts in the :10-222A/28-2  for attaching the :10-222A/28  . Not the bolts for the bracket.

-- Install the :10-222A/28  and tighten the bolts to 8 Nm -arrows-.

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-- If there are hose and cable connections located near the engine lifting eyes for the :10-222A  , these must now be removed.

Vehicles with a 2.0L/85 kW engine:

-- Install the :10-222A  as shown.

-- First slide the Moveable Joints -2- onto the Square Pipe from the :10-222A  .

• The bolts for the :T40091/3  -2- on the :10-222A  face toward the front of the vehicle.

-- Mount the :10-222A  on the suspension strut towers and have a second technician hold it to prevent it from tipping.

-- Push the :T40091/1  -5- from the front left and right through the :10-222A/28  -6- and place on each side of the :T40093/4  -4-.

-- Slide the :T40091/2  -8- with the :T40093/5  -9- in the :T40093/4  -4-.

-- Install the locking pins into the :T40091/2  -8- and secure it with the cotter pins.

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1. Engine Support Bridge - Engine Support 31 - Adapter 2 :10-222A/31-2 
2. Engine Support - Basic Set - Moveable Joint :T40091/3 
3. Engine Support Bridge - Engine Support 31 - Adapter 1 :10-222A/31-1 
4. Movable Joint :T40093/4 
5. Engine Support - Basic Set - Square Pipe :T40091/1 
6. Engine Support Bridge - Engine Support 28 :10-222A/28  with Engine Support Bridge - Engine Support 28-2 :10-222A/28-2 
7. Engine/Gearbox Support Shackle :10-222A/12 
   • Engaged in the engine lifting eye.
8. Rail with Holes :T40091/2 
9. Mount :T40093/5 
10. Engine Support Bridge - Spindle : 10-222A/11 
    • Engage in the Engine/Gearbox Support Shackle (2 pc.) :10-222A/12  .

Vehicles with a 1.6L/77 kW engine:

Install the :10-222A  as shown.

-- First slide the Moveable Joints -2- onto the Square Pipe from the :10-222A  .

• The bolts for the :T40091/3  -2- on the :10-222A  face toward the front of the vehicle.

-- Mount the :10-222A  on the suspension strut towers and have a second technician hold it to prevent it from tipping.

-- Push the :T40091/1  -5- from the front left and right through the :10-222A/28  -6- and place on each side of the :T40093/4  -4-.

-- Push the :T40091/2  -7- with the :T40093/5  -8- in the :T40093/4  -4-.

-- Install the locking pins into the :T40091/2  -7- and secure it with the cotter pins.

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1. Engine Support Bridge - Engine Support 31 - Adapter 2 :10-222A/31-2 
2. Engine Support - Basic Set - Moveable Joint :T40091/3 
3. Engine Support Bridge - Engine Support 31 - Adapter 1 :10-222A/31-1 
4. Movable Joint :T40093/4 
5. Engine Support - Basic Set - Square Pipe :T40091/1 
6. Engine Support Bridge - Engine Support 28 :10-222A/28  with Engine Support Bridge - Engine Support 28-2 :10-222A/28-2 
7. Rail with Holes :T40091/2 
8. Mount :T40093/5 
9. Engine Support Bridge - Spindle : 10-222A/11 
   • Engaged in the engine lifting eye -arrow-.

Continuation for All Vehicles 

-- Tighten all the threaded connections on the :10-222A  hand-tight. While doing so, adjust the height of the :10-222A  parallel over the :10-222A/28  .

-- Lightly tension the engine/transmission assembly via the :10-222A  spindle, do not lift.

-- Raise the vehicle and remove the left front wheel.

-- Remove the noise insulation. Refer to NOISE INSULATION .

-- Remove the left front wheel housing liner. Refer to WHEEL HOUSING LINER .

Vehicles with Power Steering 

-- Remove the bracket with the power steering line -A- from the transmission -arrows-.

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Continuation for All Vehicles 

-- Disconnect the connector -1- from the Back-Up Lamp Switch -F4-.

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-- If a nut -2- is installed, it must be removed now.

-- Remove bracket from lower starter bolt, if equipped.

-- Remove the lower bolt -3- from the starter and then remove the starter. Refer to STARTER .

-- Separate the exhaust system at the double clamp and remove the exhaust pipe bracket from the subframe. Refer to EXHAUST PIPES/MUFFLERS (CPLA, CPPA, CPKA, CPRA) , or EXHAUST PIPES/MUFFLERS (CBPA, CKJA) , or EXHAUST PIPES/MUFFLERS (CVCA, CUUA, CUUB, DELA, DEBA, DEJA & DGMA) , or EXHAUST PIPES/MUFFLERS (CNLA, CRJA) .

-- Remove the heat shield above the right drive axle -arrows-.

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-- Remove the drive axles from the flange shafts and tie them up as high as possible. Be careful not to damage the surface protection. Refer to DRIVE AXLE .

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-- Remove the pendulum support. Refer to SUBFRAME MOUNT (CZCA, CZDA, CZTA) , or SUBFRAME MOUNT (CBPA, CKJA) , or SUBFRAME MOUNT (CNLA, CRJA) , or SUBFRAME MOUNT (CPLA, CPPA, CPKA, CPRA) .

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-- If equipped, remove engine/transmission connecting bolt -arrow- in area of right flange shaft. Use the connector :T10061  to do so.

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-- Remove the cover plate -A- -arrows-, if equipped.

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-- Remove the left assembly mounting hex bolts -arrows- from the transmission mounting.

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-- Carefully move the engine/transmission subassembly into an angled position. To do so lower the engine/transmission assembly using the :10-222A  spindle.

• The bolts -arrows- for the transmission support must be accessible.

-- Remove the transmission support from the transmission -arrows-.

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The :3282  is aligned with the :3282/31  in order to remove the "0AF" transmission.

-- Insert the :3282  into the :VAS6931  .

-- Align the arms of the Transmission Support so that they match up with the holes in the Adjustment Plate.

-- Install the Support Elements -A- as illustrated on the Adjustment Plate.

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-- Install the Mounting Element -C- instead of the :3282/45  .

-- Position the Engine-Transmission Jack under the vehicle. The arrow symbol -B- on the Adjusting Plate points in the direction of travel.

-- Align the Adjustment Plate so that it is parallel to the transmission.

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-A- = :3282/45  with M 8 collar nut.

-- Install the M8 collar nut on the :3282/45  to secure the transmission.

-- Remove the engine/transmission connecting bolt -arrow-.

-- Remove the lower engine/transmission bolts.

-- If the vehicle has a metal oil pan, in the area of the oil pan remove the cover plate -arrows-.

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-- Remove the transmission from the alignment bushings and carefully move it toward the subframe.

-- Be careful of the intermediate plate on the engine.

-- Carefully push the engine slightly forward with a second technician.

-- Then carefully guide transmission with right flange shaft, as shown, onto flywheel/intermediate plate -arrow 2-.

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-- Lower the transmission carefully. When doing this, be careful of the subframe -arrow 1-.

-- Guide the transmission past the power steering line, if installed, and past the subframe when lowering it.

-- Use spindles on the :3282  to adjust the position of the transmission while lowering it.