Volkswagen Workshop Service and Repair Manuals

Removing –  If noise insulation is installed below engine/gearbox, install it → General body repairs, exterior; Rep. gr.50. –  Mark position of propshaft with flexible coupling relative to bevel box flange.

–  Unbolt propshaft with flexible coupling from bevel box flange -arrows-. –  Remove charge air pipe between charge air cooler and turbocharger → Rep. gr.21. –  Remove right drive shaft → Running gear, axles, steering; Rep. gr.40. –  Separate exhaust system at double clamp → Rep. gr.26.

–  Remove pendulum support from subframe -arrows A-. –  Carefully press engine and gearbox forwards.

–  Carefully pull front propshaft off centring pin -arrow-.   Note Do not damage seal in the propshaft flange during removal or installation.

–  Unbolt charge air control pressure unit -1- for charge pressure control valve -arrows- from turbocharger and tie up → Rep. gr.21. –  Place drip tray under gearbox and engine. –  Unbolt turbocharger oil return line -2- from engine → Rep. gr.21.

Vehicles through 09.00 –  Remove bevel box carrier from engine and bevel box -arrows-.   Note The gearbox carrier cannot be removed until bevel box has been pulled off gearbox.

Vehicles from 10.00 –  Unbolt bevel box carrier from engine and bevel box -bolts -A-, -B- and -C-.   Note The gearbox carrier cannot be removed until bevel box has been pulled off gearbox. Continuation for all vehicles –  If present, remove turbocharger bracket → Rep. gr.21. –  Place drip tray under gearbox and engine.

–  Remove oil drain plug -arrow A-. –  Drain gear oil from bevel box. –  Remove right flange shaft bolt using socket -V.A.G 1669- or commercially available 6 mm socket -arrow-. –  Remove bevel box/gearbox connecting bolts. –  Press bevel box off gearbox. –  Remove bevel box carrier. –  Remove bevel box.