Volkswagen Workshop Service and Repair Manuals

Removing gearbox –  First check whether a coded radio is fitted. If so, obtain anti-theft code. –  With ignition switched off, disconnect battery earth strap → Electrical system; Rep. Gr.27. –  If the lifting eyes of the engine for support bracket -10 - 222 A- are covered by a component, for example the air filter, it must be removed now → Rep. Gr.23 or → Rep. Gr.24 –  Then remove complete air filter housing → Rep. Gr.23 or → Rep. Gr.24. –  Remove battery, battery cover and battery tray → Electrical system; Rep. Gr.27. –  Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

–  Pull gear selector cable off pin. Metal relay lever –  Remove securing clip -arrow 2- for gate selector cable from relay lever -B-. –  Pull gate selector cable from pin. –  Pull securing clip -arrow 3- off relay lever -B- and remove relay lever. Plastic relay lever –  Remove relay lever together with cable end-piece → Chapter. Continuation for all –  Remove gearbox selector lever -A- by removing nut -arrow 4- (⇒ previous figure).

–  Remove cable support bracket from gearbox -arrows-. –  Then raise and secure gear selector cable and gate selector cable. –  Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.

–  Then remove gearbox support -arrow A-. –  Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes.   Caution Do not operate clutch pedal any more. –  Remove earth strap at upper engine/gearbox connecting bolt.

–  Pull connector -arrow 1- off reversing light switch -F4-. –  Now remove connector -arrow 2- and wire -arrow 3- from starter. –  Then remove upper securing bolt on starter. –  Remove upper engine/gearbox connecting bolts.

–  Remove breather pipe, if present, from bevel box -arrow-. –  Remove bump stop from upper edge of wing on left and right → General body repairs, exterior; 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- together with adapters -10-222 A /13- and hooks -10 - 222 A /10- in front of bonnet struts. –  Attach hooks -10 - 222 A /10- to engine. –  Take up weight of engine/gearbox assembly on hooks -10 - 222 A /10-. –  Loosen wheel bolts on front left and front right. –  Raise vehicle. –  Remove front wheels. –  Remove noise insulation and lower part of front left and right wheel housing liners → General body repairs, exterior; Rep. Gr.66. –  Remove retainer with electrical wiring from below starter bolt. –  Remove starter → Electrical system; Rep. Gr.27.

–  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 left support for exhaust manifold -A- from bevel box and exhaust manifold (bolts -2- and -3-) → Rep. Gr.26.

–  Remove bolts -2- and -3- for pendulum support on 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 with wire. –  Remove left and right coupling rods from anti-roll bar.

–  Unscrew nuts -arrows- for swivel joint and 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.

–  If present, remove shield for right drive shaft from bevel box -arrows-. –  Remove left and right drive shafts from flange shafts of gearbox. Secure drive shafts to body using wire, taking care not to damaged surface protection.

–  Remove bevel box carrier bolts from bevel box -arrows 1- and engine -arrows 2-. –  Remove bevel box carrier.

–  Remove right support -A- for exhaust manifold → Rep. Gr.26.

–  Remove small cover plate -A- behind bevel box, if present -arrow-.

–  Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting. –  Tilt engine and gearbox assembly by lowering via hooks -10 - 222 A /10- of support bracket -10 - 222 A-.   Note t  Lower threaded spindle of hook -10 - 222 A /10- using winged nut, but not more than until spindle is flush with nut. t  Be careful of all lines when lowering gearbox.

l  Securing bolts -arrows- for gearbox bracket -A- must be accessible. –  Remove gearbox bracket -A--arrows-. –  Remove starter → Electrical system; Rep. Gr.27. To remove gearbox “02S four-wheel drive”, set up gearbox support -3282- with adjustment plate -3282/39-. –  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.

–  Screw in support elements-A - and -C- on adjustment plate as shown. –  Position engine and gearbox jack -V.A.G 1383 A- under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.

–  Align adjustment plate parallel to gearbox and lock safety support on gearbox. –  Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support. –  Remove lower engine/gearbox connecting bolts. –  Separate exhaust system if lower bolts -arrows- cannot be removed.

→ Rep. Gr.26

–  Press gearbox off dowel sleeves and carefully lower. –  Have a second mechanic push engine forwards slightly. –  When lowering gearbox, change position of gearbox using spindles of gearbox support -3282-.   Note t  When lowering gearbox, observe electromechanical steering box. t  Be careful of all lines when lowering gearbox.