Volkswagen Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ Engine support bracket 10-222A with supports10-222A/1
• ◆ Socket 6 mm AF V.A.G 1669
• ◆ Drip tray

Removing

• ‒ For vehicles with coded radio obtain radio code.

• ‒ With the ignition switched off disconnect the battery earth strap.
• ‒ → Remove right-hand engine console/sub-frame securing bolt (arrow), first remove cable connector retaining plate -A- if fitted.

• ‒ → Fit support bar 10-222 A together with legs 10-222 A/1 and support engine/gearbox.

Note:

Before fitting the support hooks of the support bar, remove hose and wire connections from engine in the area of the lifting eyes, so that they are not damaged.

• ‒ Take weight of engine/gearbox assembly on the spindles.

• ‒ → If fitted, remove air duct -A- for cooling the propshaft bearing (arrow 1) and pull off from front fan connection.
• ‒ Remove power assisted steering pipe bracket from gearbox.

• ‒ → Remove front console (bolts -A- and -B-).
• ‒ Remove front engine mounting (bolt -C-).

• ‒ → Remove hexagon bolt -A- from left-hand gearbox assembly mounting -B-.

• ‒ → Remove bevel box carrier from engine and bevel box (arrows) -A-, -B- and -C-.

• ‒ → If fitted cut balance weight mounting (arrows) on assembly carrier off flush using body saw V.A.G 1523. Do not damage assembly carrier.

• ‒ If necessary repair paint work damage as follows:
  Remove grease remains with Nitro thinners L 001 600.
  Apply 2 component acrylic paint (ALN 769 041 with hardener ALZ 009 001).

• ‒ Separate exhaust system behind front exhaust pipe.

=> Repair group 26; Removing and installing parts of exhaust system, four wheel drive.

• ‒ Remove heat shield above catalyst.
• ‒ Secure catalyst in lowered position.
• ‒ Mark position of propshaft with flexible coupling to bevel box flange.
• ‒ → Disconnect propshaft flexible coupling from bevel box flange (arrows).
• ‒ Push propshaft back onto stop.

Note:

→ When removing and installing the gearbox do not damage the sealing ring in the propshaft flange.

• ‒ Disconnect right drive shaft from gearbox.
• ‒ Tie right drive shaft up as high as possible, when doing this do not damage surface protection.

• ‒ Place container under the gearbox.
• ‒ Lever out drive flange sealing cap with a screwdriver.
• ‒ Remove drive flange counter sunk head bolt with V.A.G 1669 or 6 mm socket insert cone (commercially available) and counter hold against turning with a drift.
• ‒ Pull drive shaft with drive flange out carefully and note spring behind drive flange.
• ‒ Remove bevel box/gearbox securing bolts.
• ‒ Press bevel box off gearbox.

• ‒ Take bevel box out downwards between assembly carrier and sump, to do this push engine/gearbox assembly forwards (2nd mechanic).

Note:

→ When removing and installing the gearbox do not damage the seal in the propshaft flange.

• ‒ Take out bevel box.

Installing

Installing gearbox is carried out in the reverse sequence. When installing gearbox ensure engine/gearbox mountings are installed stress-free.

=> Repair group 10; removing and installing engine.

Notes:

• ◆ Build bevel box on as follows:

• ‒ → Always replace sealing ring to seal bevel box/gearbox (arrow A) and sealing rings to seals sleeves for the oil supply system (arrow B and C), lightly coat with oil.
• ‒ Push bevel box completely onto gearbox, thereby ensuring that the bevel box input shaft teeth are guided centrally onto the differential connecting piece.
• ‒ If the teeth position and the central guide are correctly set then the bevel box will slide onto the stop against the gearbox.
• ‒ Do not pull the bevel box onto the gearbox using securing bolts otherwise the bevel box will cant and the securing eyes can break off.

• ◆ When installing the gearbox carrier note following assembly sequence:

• ‒ → Tighten bolts -A- to 25 Nm.
• ‒ Tighten bolts -B- and -C- to 40 Nm.

• ◆ When removing and installing do not damage seals in propshaft flanges.
• ◆ Renew propshaft if damaged.
• ◆ Ensure propshaft is horizontal when pushing onto guide pins.
• ◆ Replacing drive shaft seal.

=> Running gear; Repair group 40; Servicing drive shaft

• ◆ Installing front exhaust pipe to catalyst

=> Repair group 26; Removing and installing parts of exhaust system.

• ◆ Checking oil in gearbox with bevel box .
• ◆ Adjusting gear selector mechanism .

Tightening torques =>from Page 34-51