Volkswagen Workshop Service and Repair Manuals

Removing gearbox –  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. 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.23 or → Rep. gr.24. –  Remove battery and battery tray → Electrical system; Rep. gr.27.

–  Remove securing clip -1- for gear selector cable from gearbox selector lever -2- and pull cable off pin -arrow-.

–  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 relay lever is removed together with the cable end-piece at a later point.

–  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 -1- from top starter bolt. –  Separate electrical connector -2- for reversing light switch -F4-. –  Remove connector and wire from starter.

–  Remove upper engine/gearbox connecting bolts -arrows-. –  Then remove upper securing bolt on starter.

–  Bolt bracket -T10346- to rear of the 3 mounting holes for battery tray. –  To do this, use a collar bolt M 6 x 80 or a securing bolt for battery tray. –  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 /8- t  Adapter -10-222 A /18- –  Position adapter -10-222 A /8-: l  On upper longitudinal carrier, directly before the elevation (-arrow 1-) next to bolt (-arrow 2-) –  Connect bracket -T10346- to support bracket. –  Attach spindles in left engine support eyes. –  Take up weight of engine/gearbox assembly and support bracket on spindles.

The left drive shaft will be removed in a later step. –  While vehicle is still standing on its wheels, loosen front left flange bolt -arrow- by a maximum of 90° or wheel bearing will be damaged. → Running gear, axles, steering; Rep. gr.40 –  Remove noise insulation → General body repairs, exterior; Rep. gr.50. –  Remove lower part of front left wheel housing liner → General body repairs, exterior; Rep. gr.66.

–  Gearboxes for vehicles with start-stop system: pull connector -arrow- off gearbox neutral position sender -G701-.

–  If fitted, unbolt front vehicle level sender -G78- from transverse link → Rep. gr.40. –  Remove bracket from starter. –  Remove starter → Electrical system; Rep. gr.27.

–  Remove left charge air hose -arrow 1- and -arrow 2- → Rep. gr.21. –  Remove charge air pipe from engine → Rep. gr.21. –  Remove right charge air hose from charge air cooler → Rep. gr.21.

–  Remove cowling -arrow- together with radiator fans. → Rep. gr.19

–  Remove exhaust system bracket from subframe -arrows- → Rep. gr.26.

–  Separate exhaust system at double clamp -arrows-. –  Raise and secure front exhaust pipe or rest it on tunnel bridge.

–  Remove pendulum support.

–  Pull connector -1- off oil level and oil temperature sender -G266-. –  Remove left coupling rod from anti-roll bar and lay to side. → Running gear, axles, steering; Rep. gr.40 –  Remove left drive shaft. → Running gear, axles, steering; Rep. gr.40

–  Remove drive shaft heat shield, if present -arrows- → Running gear, axles, steering; Rep. gr.40. –  Remove right-hand drive shaft from gearbox and tie up. → Running gear, axles, steering; Rep. gr.40

–  Remove hexagon bolts -arrows- on left engine/gearbox mounting -2- from bracket -1-.

–  Lower gearbox about 40 mm, dimension -a-, by adjusting spindles attached to engine.   Note Observe connecting lines, hoses and radiator when moving engine/gearbox assembly.

–  Remove bracket -1- from gearbox -arrows-. –  Remove relay lever together with cable end-piece → Chapter. –  Remove gearbox selector lever from selector shaft.

–  If small cover plate -A- for flywheel is present, remove it -arrows-.

–  Remove lower engine/gearbox connecting bolt -1-.   Note Loosen engine/gearbox connecting bolt -3- and leave it installed just hand-tight.

–  Attach bracket -T10346- with bolt -1- to left threaded hole in subframe. -1- = Flange bolt M6 x 20. –  Secure engine support -3300 A- to bracket -T10346-. –  Place a cloth between engine support -3300 A- and oil pan.

–  Press engine forwards using spindle of engine support -3300 A-. In the process, observe the following points in particular: l  The air conditioning compressor -2- must not contact -arrow- the refrigerant line -1-. l  The alternator must not contact the refrigerant line. l  The pressure pipe must not contact the radiator.

To remove gearbox „02Q“, 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 -V.A.G 1383 A- under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel. –  Align adjustment plate parallel to gearbox.

–  Attach adapter -VW 771/40- in threaded hole of gearbox housing as shown in illustration. –  Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support. –  Secure gearbox to gearbox support -3282- using bolt (M10x20) -A-.

Pin -B- must lie flush with guide from gearbox support -3282- at bottom -arrow-. Engine/gearbox connecting bolt -arrow- has been removed. –  Remove engine/gearbox connecting bolt (item -C-, ⇒ previous diagram) and remove lower engine/gearbox connecting bolts. –  Press gearbox away from engine, off dowel sleeves. –  Tilt gearbox in area of differential using spindles of gearbox support -3282-. l  Differential must face upwards.

Right flange shaft -1- must be guided past bolt hole of engine -2-.

–  Guide gearbox with differential -A- over subframe and swing out.

–  Observe longitudinal member -arrows-. Then carefully lower gearbox.   Note Be careful of all lines when lowering gearbox.