Volkswagen Workshop Service and Repair Manuals

Removing

• ‒ Disconnect earth strap from battery

Note:

Note radio coding for vehicles with coded radio.

On vehicles with G charger:

• ‒ Remove charged air hose.

=> Repair group 21; Removing and installing parts of exhaust system

• ‒ Remove radiator cover.

On vehicles with electronic speedometer:

• ‒ → Pull connector off 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.
• ‒ Remove hexagon bolt with threaded sleeve from gear stick 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.

On vehicles with mechanical speedometer:

• ‒ Disconnect speedometer drive cable from gearbox with key 3016.

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

• ‒ → Remove 3 bolts -A- from right hand engine mounting -B-. First remove connector mounting plate if fitted.

• ‒ Remove earth strap at engine/gearbox upper securing bolt.
• ‒ Remove upper rear engine/gearbox securing bolts and loosen front securing bolts.
• ‒ → Remove hexagon bolt -C- from left hand gearbox mounting -D-.
• ‒ If fitted remove retaining bracket for coolant hose, coolant pipe and securing plate for electrical connections from front of console.

• ‒ → Remove nuts -A- for front of console -B-.

• ‒ → 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 starter.

=> Repair group 27; Removing and installing starter.

• ‒ Remove power assisted steering pipe bracket from gearbox.
• ‒ Remove front console.
• ‒ → Remove front engine mounting. To do this remove bolts items -a- and -c- (nut item -b- already removed).

• ‒ → Remove vibration damper -A- from sub-frame. Mark installation position.
• ‒ Separate exhaust system behind down pipe.

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

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

• ‒ → Remove left-hand air deflector -A-, by driving clips out with a drift through holes in wishbone (arrows).
• ‒ Disconnect drive shafts from flanged shafts, turn steering to full left lock.
• ‒ Push engine/gearbox assembly as far forwards as possible, if necessary with help of a second mechanic.
• ‒ Tie-up right-hand drive shaft as high as possible,
• ‒ Tie-up left-hand drive shaft forwards on wishbone.
• ‒ 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.

Note:

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

• ‒ → Remove flywheel small cover plate -A- behind the right-hand flanged shaft (arrows).
• ‒ Remove large flywheel cover plate.
• ‒ Lower engine/gearbox assembly via both spindles to previous position, push as far as possible to the right and lower slightly using left spindle.

On vehicles with 4 valve engine:

• ‒ → Remove additional support between gearbox and engine in area of clutch housing by removing bolts -A- and -B-.

• ‒ Remove lower engine/gearbox securing bolt.
• ‒ → Set up press tool 3300 A .
• ‒ Press engine and gearbox forwards.

Note:

Do not damage P.A.S pipe.

• ‒ Remove forward bolt from upper engine/gearbox support.
• ‒ 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 Page 34-31 ) on adjustment plate points to front of vehicle.
• ‒ Align adjustment plate parallel to gearbox and lock safety supports on gearbox.
• ‒ 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.

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

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

No. of holes visible = 5

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

Installing

Installing gearbox is carried out in the reverse sequence. When installing gearbox ensure engine/gearbox mountings are installed stress-free.

=> Repair group 10; removing and installing engine.

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.
• ◆ When replacing the gearbox ensure that the intermediate plate is correctly positioned.
• ◆ Check whether dowel sleeves for aligning engine/gearbox are fitted in cylinder block, install if necessary.

• ◆ → Additionally tighten support between gearbox and engine on vehicles with four valve engine as follows:
• ‒ Tighten all bolts hand-tight.
• ‒ Tighten bolts -A- to torque setting.
• ‒ Tighten bolts -B- to torque setting.
• ◆ Tie left-hand drive shaft up forward on wishbone before installing gearbox console. When doing this ensure there is sufficient clearance between constant velocity joint and flange shaft (2nd mechanic).

• ◆ Replacing drive shaft seal.

=> Running gear; Repair group 40; Servicing drive shaft

• ◆ Installing starter/wiring.

=> Repair group 27; Removing and installing starter.

• ◆ Checking gearbox oil .
• ◆ Adjust gear change linkage .

Tightening torques

→ Gearbox to engine

     1)     Also starter to gearbox

     2)     Flywheel large cover plate (not on vehicles with 4 valve engine)

     3)     Flywheel small cover plate

Pos. A + B - Dowel sleeves

→ Assembly mountings

→ Front engine mounting to: