Volkswagen Workshop Service and Repair Manuals

Removing gearbox –  First check whether a coded radio is fitted. If so, obtain anti-theft code. –  Remove battery and battery tray → Electrical system; Rep. gr.27. At a later point, the support bracket -10-222 A- will be connected to the lifting eyes of engine. –  If engine cover blocks access, remove engine cover. –  Remove complete air filter housing if it is located close to the battery. → Rep. gr.24

–  Remove line -1- from air filter bracket -2-. –  Remove bolts -arrows- and remove air filter bracket.

–  Remove securing clip -3- for gear selector cable from gearbox selector lever -1- and pull cable off pin -arrow-. Metal relay lever –  Remove securing clip -4- for gate selector cable from relay lever -2- and pull cable off pin -arrow-. Plastic relay lever

Releasing cable end-piece from gate selector cable l  To avoid damage to gate selector cable, separate cable end-piece from gate selector cable before removal. –  Pull locking mechanism forward to stop in -direction of arrow 1- and then lock by turning to left in -direction of arrow 2-. –  Then push relay lever forwards (-in direction of arrow 3-). –  The plastic relay lever is removed together with the cable end-piece at a later point. Continuation for all

–  Remove cable support bracket from gearbox -arrows-, lay to side and secure with wire.

Vehicles with pipeline between master and slave cylinder –  Clamp off supply hose to master cylinder using hose clamp -3094-.

Vehicles with pipe/hose assembly between master and slave cylinder –  Clamp off hose of pipe/hose line -A- to slave cylinder using hose clamp -3094-. Continuation for all –  Pull out clip -arrow- for pipe/hose line or pipeline to stop. –  Pull pipe/hose line or pipeline out from slave cylinder bleeder and seal.   Caution Do not operate clutch pedal any more. –  Remove earth strap from top starter bolt. –  Remove connector and wire from starter.

–  Remove upper engine/gearbox connecting bolts -arrows-. –  Then remove upper securing bolt on starter. –  Remove both foam pieces from upper edge of left and right wings → Body, front; Rep. gr.50. –  If there are hose and cable connections in area of engine support eye for support bracket -10-222 A-, remove these now.

–  Set up support bracket -10-222 A- in front of bonnet support. Use: t  Adapter -10-222 A /3- t  Adapter -10-222 A /13- t  Adapter -10 - 222 A /18- –  Take up weight of engine/gearbox assembly on spindles. –  Loosen wheel bolts on front left and front right. –  Raise vehicle. –  Remove front wheels. –  Install lower part of front left wheel housing liner → General body repairs, exterior; Rep. gr.66. –  Install noise insulation → General body repairs, exterior; Rep. gr.50.

–  Separate electrical connector -2- for reversing light switch -F4-. –  Remove nuts -1- and remove retainer with electrical connections from lower starter bolt. –  Remove starter → Electrical system; Rep. gr.27. –  Remove air conditioner compressor with refrigerant hoses attached from ancillary bracket for air conditioner compressor. Tie air conditioner compressor to body → Heating, air conditioning; Rep. gr.87.

–  Remove exhaust system bracket from subframe -arrows-.

–  Separate exhaust system at clamp -arrows-. –  Raise exhaust pipe and secure.

–  Mark position of propshaft with flexible coupling relative to bevel box flange. –  Unbolt propshaft with flexible coupling from bevel box flange -arrows-.

–  Pull connector -1- off oil level and oil temperature sender -G266-.

–  Remove pendulum support from gearbox.   Note

After pendulum support securing bolts are loosened, the engine/gearbox assembly will swing slightly forwards (towards front of car). Ensure that seal -arrow- in flange of propshaft is not damaged during removal or installation. –  Press gearbox/engine assembly forward slightly and then pull propshaft out of bevel box. –  Raise propshaft and secure. –  Remove left and right coupling rods from anti-roll bar.

–  Unscrew nuts -arrows- for swivel joint on suspension links. –  Remove steering box from subframe, raise and secure. –  Fix position of subframe prior to removal → Running gear, axles, steering; Rep. gr.40. –  Remove subframe with pendulum support, anti-roll bar, brackets and suspension links → Running gear, axles, steering; Rep. gr.40.

–  Unbolt heat shield for right drive shaft from bevel box -arrows-. –  Remove left and right drive shafts from flange shafts of gearbox. Secure drive shafts, taking care not to damaged surface protection.

–  Remove bolts -arrows- for bevel box carrier from engine and bevel box. –  Remove bevel box carrier.

–  Remove bolt -arrow- above bevel box.

–  Position engine and gearbox jack -V.A.G 1383 A- with universal support -V.A.G 1359/2- under gearbox near differential and exert slight counter pressure. A -  Wooden block

–  Remove assembly mounting bolts -arrows- at gearbox.   Note Use stepladder -VAS 5085- to remove securing bolts.

–  Lower gearbox by adjusting spindles of support bar -10 - 222 A- while simultaneously lowering with the engine and gearbox support -V.A.G 1383 A- by the dimension -a-. l  Dimension -a- = about 60 mm –  Remove engine and gearbox jack -V.A.G 1383 A- with universal support -V.A.G 1359/2- from beneath gearbox.

–  Unbolt bracket from gearbox -arrows-.

Metal relay lever –  Pull securing clip -arrow- off relay lever -1- and remove relay lever. Plastic relay lever –  Remove relay lever together with cable end-piece → Chapter. Continuation for all –  Remove gearbox selector lever from selector shaft.

–  Remove engine/gearbox connecting bolt -arrow- next to secondary air pump.

–  Remove engine/gearbox connecting bolt -arrow- next to bevel box -C-. There may be securing clip -A- for bolt -arrow- installed in the engine sump -B-.

To remove gearbox „02Q four-wheel drive“, set up gearbox support -3282- with adjustment plate -3282/33-. –  Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383 A-. –  Align arms of gearbox support according to holes in adjustment plate. –  Attach support elements-A- to adjustment plate as illustrated. –  Screw in pin -3282/29- in place of support element-C-. –  Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel. –  Align adjustment plate and gearbox parallel to one another. –  Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

–  Secure adapter -VW 771/40- in threaded hole of gearbox housing as shown in figure. –  Secure gearbox to gearbox support -3282- using bolt (M10x20) -A-.

–  Remove last engine/gearbox connecting bolts -1...3-.

–  Press gearbox off engine and tip upwards in vicinity of differential. In the process, guide past propshaft -A- and front exhaust pipe -B- with output flange -C-. If necessary, rotate output flange. Also observe area between bevel box and intermediate plate of engine. –  Lower gearbox carefully.   Note When lowering gearbox, observe steering box.