Volkswagen Workshop Service and Repair Manuals

Removing

• ‒ Disconnect earth strap from battery.

Note:

For vehicles with coded radio obtain radio code.

• ‒ Remove battery.
• ‒ Remove air filter upper section.
• ‒ Remove radiator cover.
• ‒ → Remove bolt (arrow) on engine console/sub-frame, right. If fitted remove connector mounting plate -A-.
• ‒ Remove earth strap from engine/gearbox upper securing bolt if fitted.

• ‒ → Pull connector off speedometer sender (arrow 1).
• ‒ Pull reverse light connector off (arrow 2). Disconnect all other electrical connections and earth cables from gearbox and from the engine/gearbox securing bolts.

• ‒ → Remove balance weight -A- and gear selector cable -B- from gear selector lever.
• ‒ Pull gate selector cable -C- off actuating arm/relay lever, to do this lift lug in direction of arrow.

• ‒ Unclip slave cylinder hose at cable support bracket.
• ‒ → Remove cable support bracket from gearbox (arrows) and lay to one side.

• ‒ → Remove slave cylinder and secure to side with wire, do not disconnect pipe.

• ‒ Remove upper engine/gearbox securing bolts.
• ‒ Remove coolant system expansion reservoir and lay to one side.
• ‒ → Remove gearbox hexagon bolt -C- gearbox from left assembly mounting -D-.

• ‒ If fitted remove electrical connector securing plate from front console.
• ‒ → Remove bolts -1- for console and -2- for assembly mounting.

• ‒ → Fit support bar.

Note:

Before fitting the support hooks of the support bar, remove hose and wire connections from engine in the area of the lifting eyes, so that they are not damaged.

• ‒ Take-up weight of engine/gearbox assembly via the spindles.
• ‒ Remove lower ribbed belt guard/engine.
• ‒ Remove insulation tray below engine/gearbox.
• ‒ Remove starter.

=> Repair group 27; Removing and installing starter.

Note:

Before removing the lower starter securing bolt remove P.A.S. pipe retainer from gearbox.

• ‒ Remove front console.

• ‒ → Remove balance weight -A- from sub-frame.
• ‒ Separate exhaust system in front of catalyst.

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

• ‒ Disconnect drive shafts from flanged shafts, turn steering to full left lock and tie-up drive shaft as high as possible, when doing this do not damage surface protection.

• ‒ Push engine/gearbox assembly as far as possible to right.
• ‒ → Remove gearbox console -A- from gearbox.
• ‒ When doing 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.

• ‒ → Press engine/gearbox assembly towards bulkhead using lug -A-, do not damage P.A.S. pipe.
• ‒ Remove gearbox console securing bolt -B- from below support (arrow => Fig. V34-2669 on Page 34-44 ).
• ‒ Lower engine/gearbox assembly via both spindles to previous position, then incline engine by turning left hand spindle.
• ‒ Remove clutch cover plate.
• ‒ Remove engine/gearbox securing bolts above the right flanged shaft.
• ‒ 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.

Note:

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 with gearbox support under vehicle, arrow symbol -B-(=>Illustration V34-2670 on page 34-45 ) on adjustment plate points to front of vehicle.
• ‒ Align adjustment plate parallel to gearbox and lock safety supports on gearbox.
• ‒ Remove lower engine/gearbox securing bolt.
• ‒ Press gearbox off dowel sleeves.

Note:

Gearbox cover must lightly contact left-hand longitudinal member.

• ‒ → Press engine forwards with support appliance 3300 until it just touches the engine sub-frame.
• ‒ Lower gearbox. When lowering gearbox, constantly adjust position via the spindles on the gearbox jack.

Note:

When lowering do not damage the P.A.S pipe.

• ‒ → 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

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

=> Repair group 10; removing and installing engine.

Notes:

• ◆ → When replacing gearbox, the senders for speedometer (Fig.), gear selector lever and relay lever must be transferred to the new assembly.
• ◆ Check whether dowel sleeves for aligning engine/gearbox are fitted in cylinder block, install if necessary..
• ◆ Clean input shaft splines and lightly grease with G000 100 grease.

• ◆ → 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.
• ◆ Before joining gearbox to engine remove support device 3300.
• ◆ Checking gearbox oil
• ◆ Adjust gear selector mechanism => Page 34-19

Tightening torques

→ Gearbox to engine

1)Also front console to gearbox

2)Also starter and front console to gearbox

     3)Flywheel cover plate
          Pos. A + B - Dowel sleeves
          Lower starter to gearbox securing bolt M 10 x 42 60 Nm

→ Assembly mountings