Volkswagen Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ 10-222 A Support
• ◆ 10-222 A/1 Support
• ◆ V.A.G 1383 A Gearbox jack
• ◆ 3282 Gearbox support
• ◆ 3282/8 Adjustment plate
• ◆ 3282/48 Pin (Qty. 3)
• ◆ 3282/59 Support
• ◆ 3336 Gearbox lifting beam

Special tools and workshop equipment required

• ◆ V.A.G 1331 Torque wrench

Removing

• ‒ Remove cover from engine (arrow).

Note:

Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap must be disconnected. Obtain radio code first if necessary.

• ‒ Remove connecting pipe between charge air cooler and intake manifold pressure hose.

=> Repair group 21; Removing and installing parts of turbocharger

• ‒ → Pull connector off road speed sender (arrow 1).

• ‒ Pull off reverse light connector (arrow 2).
• ‒ Disconnect all other electrical connections and earth wires from gearbox and from the engine/gearbox securing bolts.

• ‒ → Remove balance weight -A- and gear selector cable -B- from gear selector lever.
• ‒ Take off gear selector cable with washer and square nut (self-locking).
• ‒ Pull gate selector cable off actuating arm/relay lever -C- to do this lift lug in direction of arrow.

• ‒ → Remove cable support bracket from gearbox (arrows), if necessary unclip hose at cable support bracket first.

• ‒ → Remove slave cylinder place to side and secure with wire, do not disconnect pipes.

Note:

Do not depress clutch pedal.

• ‒ Remove air hose from between air cleaner and air intake elbow.

• ‒ → Remove bolt (arrow) on engine console/sub-frame, right. If fitted remove connector mounting plate -A-.

• ‒ → Disconnect engine carrier at front console.
• ‒ If fitted remove retaining bracket for coolant hose, coolant pipe and securing plate for electrical connections from front of console.
• ‒ Remove coolant system expansion reservoir and lay to one side.

Note:

Do not open cooling system.

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

• ‒ → Remove bolts -A- and -B- and detach left gearbox console from body.

• ‒ → Remove nuts -A- and bolts -B- and detach right engine console from the body.

• ‒ Remove earth strap at engine/gearbox upper securing bolt.
• ‒ Remove engine/gearbox upper securing bolts.

• ‒ → Fit support bar 10-222A together with legs 10-222 A/1.
• ‒ Take weight of engine/gearbox assembly on the spindles.
• ‒ If not already removed, remove wiring and cable from gearbox.
• ‒ Remove insulation tray below engine/gearbox, if fitted.
• ‒ Remove power assisted steering pipe bracket from starter.
• ‒ Remove starter.

=> Repair group 27; Removing and installing starter.

• ‒ Remove front console.
• ‒ Separate exhaust system in front of catalyst.

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

• ‒ Remove right hand inner constant velocity joint protective cover from engine if fitted.

• ‒ Disconnect drive shafts from drive flanges and tie-up.
• ‒ When doing this do not damage surface protection.
• ‒ → Removing gearbox console -A- from gearbox.

To do this remove gearbox console securing bolt -B- as follows:

• ‒ Lift engine/gearbox assembly via both spindles until the exhaust system contacts the heat shield; ensure that selector cable support bracket is not jammed.

• ‒ Push engine/gearbox assembly forwards (2nd mechanic required) and remove lower gearbox console securing bolt -B-.
• ‒ Then tie drive shaft up as high as possible. When doing this ensure sufficient clearance between constant velocity joint and flange shaft.
• ‒ → Remove flywheel small cover plate -A- behind the right-hand flanged shaft (arrows).
• ‒ Remove lower flywheel cover plate, if part of original equipment.

• ‒ Lower engine/gearbox assembly via both spindles to previous position, push as far as possible to the right and lower slightly using left spindle.

Note:

Do not damage P.A.S. pipe when moving engine/gearbox assembly.

• ‒ Assemble gearbox jack with gearbox support 3282, adjustment plate 3282/8 for "02A" gearbox and support elements as follows:
• ‒ Place adjustment plate 3282/8 on gearbox support 3282. (Adjustment plate only fits in one position).
• ‒ Align arms of gearbox support according to holes in adjustment plate.
• ‒ → Bolt on support elements -A-, as illustrated, on adjustment plate.

• ‒ → Place gearbox jack under vehicle, arrow symbol -B- (=> Illustration V34-2670) on adjustment plate points to front of vehicle.
• ‒ Align adjustment plate parallel to gearbox and lock safety supports on gearbox.

• ‒ Remove lower engine/gearbox securing bolt.
• ‒ Press gearbox off dowels and lower carefully while pushing engine/gearbox assembly forward slightly and constantly correct the position via the gearbox jack spindles.

Note:

Do not damage P.A.S pipe when lowering gearbox.

Transporting the gearbox

• ‒ → Bolt gearbox lifting device 3336 to clutch housing.

• ‒ → Set support arm on sliding piece with locking pin (arrow).

No. of holes visible = 5

• ‒ Lift gearbox with workshop crane and gearbox lifting device 3336.
• ‒ Place gearbox, for example onto transport container.

Installing

Notes:

• ◆ → Before installing gearbox press clutch release lever towards gearbox housing and secure with assembly pin, assembly bolt or M 8 x 35 bolt. Remove after gearbox has been installed. The hole will then be sealed by the 3rd cable support bracket securing bolt or plugged.

• ◆ → When replacing gearbox, the senders for speedometer (Fig.), gear selector and relay lever must be transferred to new assembly.

• ‒ Clean input shaft splines and lightly grease with G000 100 grease.

The clutch plate must be able to slide lightly to and fro on the input shaft.

• ‒ Check whether dowel sleeves for aligning engine/gearbox are fitted in cylinder block, install if necessary.
• ‒ Ensure that the intermediate plate is correctly positioned on engine.
• ‒ Assemble gearbox jack with gearbox support 3282, adjustment plate 3282/8 for "02A" gearbox and support elements as follows:

• ‒ Place adjustment plate 3282/8 on gearbox support 3282. (Adjustment plate only fits in one position).
• ‒ Align arms of gearbox support according to holes in adjustment plate.
• ‒ → Bolt on support elements -A-, as illustrated, on adjustment plate.

• ‒ Place gearbox on gearbox jack.
• ‒ Align adjustment plate and gearbox parallel with one another and lock safety supports on gearbox.
• ‒ → Place gearbox jack under vehicle, arrow symbol -B- (=> Illustration V34-2670 on previous page) on adjustment plate points to front of vehicle.
• ‒ Insert gearbox.

Note:

Do not damage P.A.S pipe.

• ‒ Install lower engine/gearbox securing bolts.

• ‒ Install upper engine/gearbox securing bolts.
• ‒ → Install gearbox console -A-.

Install gearbox console securing bolt -B- as follows:

• ‒ Lift engine/gearbox assembly via both spindles and push towards front end (2nd mechanic required) and then install lower gearbox console securing bolt -B-.

• ‒ Install front console.
• ‒ Install starter.

=> Repair group 27; Removing and installing starter.

• ‒ Align engine/gearbox in installation position.
• ‒ Install power assisted steering pipe bracket on starter.
• ‒ → If it was removed install small cover plate -A- behind right-hand drive flange (arrows).
• ‒ If it was removed install large cover plate for clutch.
• ‒ Fit drive shafts to gearbox.

=> Running gear, axles, steering; Repair group 40; Servicing drive shafts, Removing and installing drive shafts

• ‒ Install insulation tray below engine/gearbox, if fitted.
• ‒ Install left gearbox assembly mounting hexagon bolt.
• ‒ → Install bolt (arrow) on engine console/sub-frame, right. Fit connector mounting plate -A-, if fitted.
• ‒ Install air hose between air cleaner and air intake elbow.

• ‒ → Install front console securing bolt to engine mounting.

• ‒ → Attach left gearbox console to body with bolts -A- and -B-.

• ‒ → Attach right engine console to body with nuts -A- and the bolt -B-.

• ‒ → Align engine/gearbox mountings stress-free by shaking assembly and tighten to tightening torque.

=> Repair group 10; removing and installing engine.

• ‒ → Install engine cover (arrow).

• ‒ → Install slave cylinder

• ‒ → Connect speedometer sender connector (arrow 1).
• ‒ Connect reverse light connector (arrow 2).

• ‒ → Install cable support bracket on gearbox (arrows), if necessary push hose onto cable support bracket.

• ‒ → Install gear selector cable -B- and balance weight -A- on gear selector lever.
• ‒ Fit gate selector cable on follower/relay lever -C- to do this lift lug in direction of arrow.
• ‒ Fit connecting pipe between charged air cooler and intake manifold pressure hose.

=> Repair group 21; Removing and installing parts of turbocharger

• ‒ Secure coolant system expansion reservoir.
• ‒ Reconnect earth strap to battery.

Note:

Note radio coding for vehicles with coded radio.

• ‒ Checking gearbox oil .
• ‒ Adjusting gear change mechanism .

Tightening torques

→ Gearbox to engine

     1)     Also starter to gearbox

     2)     Only on engines with an aluminium sump,

     3)     Large cover plate for flywheel only on engines with heat steel sump (sump painted black)

     4)     Small cover plate for flywheel

Items A + B - Dowel sleeves

→ Assembly mountings

→ Gearbox console to body

→ Engine console to body