Volkswagen Workshop Service and Repair Manuals

• ‒ The engine is removed forwards together with the gearbox.
• ‒ All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
• ‒ Remove engine cover.

Note:

Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap must be disconnected. Obtain radio code first if necessary.

• ‒ With the ignition switched off disconnect battery earth strap.
• ‒ Remove battery and battery retainer.
• ‒ Disconnect clutch cable:

=> 5-speed manual gearbox 085; Repair group 30; Servicing clutch mechanism

• ‒ Remove connecting hose for air cleaner/air intake connecting piece.
• ‒ Remove intake manifold cover , Removing and installing intake manifold.

• ‒ → Disconnect fuel supply and return pipes -arrows- at injector pump.
• ‒ Seal the pipes so that the fuel system is not contaminated by dirt etc.
• ‒ Observe rules for cleanliness => Page 20-12 .
• ‒ Remove noise insulation tray.

• ‒ → Remove pendulum support.
• ‒ Separate front exhaust pipe from exhaust manifold => Page 26-2 , exhaust manifold, front exhaust pipe and catalyst with attachments.
• ‒ Disconnect cable selector mechanism from gearbox.

=> 5-speed manual gearbox 085; Repair group 34; Servicing selector mechanism (cable selector mechanism); Removing and installing selector mechanism

• ‒ Remove power assisted steering vane pump and lay to side; hoses remain connected.

=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic lines; Removing and installing power steering vane pump.

• ‒ Remove left and right-hand drive shaft on gearbox and tie up:

=> Running gear, Axles, Steering; Repair group 40; Servicing front suspension; Removing and installing drive shafts

• ‒ Open and close the expansion tank sealing cap to release pressure in cooling system.
• ‒ Drain coolant => Page 19-12 .
• ‒ Pull off coolant hose at engine with assembly tool for spring-type clamps VAS 5024.
• ‒ Removing lock carrier with attachments:

=> General body repairs, Exterior; Repair group 50; Body, front; Removing and installing lock carrier with attachments.

• ‒ Tie-up power assisted steering reservoir.

• ‒ Pull vacuum and breather hoses off engine.
• ‒ → Remove engine mounting bolt -1- and fit ring bolt 3368.

• ‒ → Attach lifting tackle 2024 A with bracket 3180 as follows and lift slightly with workshop crane:

     Pulley end:
     4nd hole in hook rail at position 1

     Flywheel end:
     1st hole in hook at position 7

Notes:

• ◆ The positions marked 1...4 on the bar must be towards the pulley end.
• ◆ The holes in the hook rails are counted up from the hook.

• ‒ → Unbolt assembly at gearbox and engine mountings -arrows-.
• ‒ Lower assembly until it is released from the gearbox mounting.
• ‒ Pull assembly out forwards. When doing this, if necessary turn assembly and lower slightly.

Note:

When the assembly is lifted off, it must be carefully guided to prevent damage to the bodywork.