Volkswagen Workshop Service and Repair Manuals

Removing

Special tools and workshop equipment required t  Support bracket -10 - 222 A- t  Rack -10 - 222 A /1- t  Engine and gearbox jack -V.A.G 1383 A- t  Gearbox support -3282- t  Adjustment plate -3282/18- t  Pin -3282/48- t  Mounting pin -3282/49- t  Support -3282/59- (2x)

t	Engine support -3300 A-

t	Support rail -T10036-

t	Gearbox mounting support -3336-

t	Torque wrench -V.A.G 1332-

Additional required information t  Workshop Manual Golf 1998 ►, Bora 1999 ► Engine, mechanics t  Workshop Manual Golf 1998 ►, Bora 1999 ►, Running gear, axles, steering front and four-wheel drive t  Workshop Manual Golf 1998 ►, Bora 1999 ► Electrical system Removing –  First check whether a coded radio is fitted. If so, obtain anti-theft code. –  With ignition switched off, disconnect battery earth strap. –  Remove cover from engine.

–  Remove intake hose -1-, connector -2- and hose -3- from air mass meter. –  Remove complete air filter housing by removing bolts -4- and -5- → Rep. Gr.24.

–  Remove cable support bracket from gearbox -arrows-, if necessary unclip hoses on cable support bracket first.

–  Pull off gate selector cable -A- with relay lever, remove securing clip -arrow- to do this. –  Remove gear selector cable -B- with gearbox selector lever, remove nut -arrow- to do this. –  Tie up selector cable with gearbox selector lever and gate selector cable with relay lever.

–  Pull connector off speedometer sender -arrow 1-. –  Pull off reversing light connector -arrow 2-.

–  Remove slave cylinder, lay to side and secure with wire. Do not disconnect pipes.   Note Do not depress clutch pedal.

–  Remove cable retainer -arrow 1- from starter. –  Remove wiring and cable from starter. –  Remove earth strap at upper engine/gearbox connecting bolt. –  Then remove upper securing bolt -arrow 2- from starter. –  Remove upper engine/gearbox connecting bolts. –  If there are hose and cable connections in area of engine support eye for support bracket -10 - 222 A-, remove these now.

–  Fit support bracket -10 - 222 A- in conjunction with racks -10 - 222 A /1-. –  Take up weight of engine/gearbox assembly on spindles. –  If present, remove wiring and cable from gearbox. –  Remove centre and left parts of noise insulation below engine and gearbox, if fitted. –  Turn wheels to left lock. –  Disconnect drive shafts from flange shafts and tie up as high as possible, being careful not to damage surface protection. –  Separate exhaust system and if necessary remove from subframe → Rep. Gr.26. –  Place drip tray under gearbox and engine.

–  Unbolt turbocharger oil return line from engine -arrow- → Rep. Gr.21.

–  Remove bevel box carrier from engine and bevel box -arrows-.

–  If small cover plate -A- for flywheel behind bevel box is installed, remove it -arrows-. –  Remove lower flywheel cover plate, if part of original equipment. –  Mark position of propshaft with flexible coupling relative to bevel box flange.

–  Unbolt propshaft with flexible coupling from bevel box flange -arrows-.

–  Then remove gearbox support -arrow A- from gearbox. –  Remove hexagon bolts -arrows B- of left-hand hand assembly mounting from gearbox mounting. –  Tilt engine/gearbox assembly by lowering the left spindle of support bracket -10 - 222 A-. l  Securing bolts -arrows- for gearbox bracket -A- must be accessible.

–  Remove gearbox bracket -A--arrows-. –  Remove power assisted steering line from starter and gearbox.

–  Bolt support rail -T10036- to both pendulum support securing holes on subframe (bolts -A-). –  Fit engine support -3300 A- so that it almost touches subframe and bolt on -arrows-. –  Carefully press engine and gearbox forwards.   Note Observe connecting lines and hoses when moving engine/gearbox assembly.

–  Remove rear lower engine/gearbox connecting bolt -arrow A-. –  Remove bolt of bevel box -arrow B- to allow the mounting pin -3282/49- of gearbox support -3282- to engage. To remove gearbox 02C with bevel box, set up gearbox support -3282- with adjustment plate -3282/18-. –  Align arms of gearbox support according to holes in adjustment plate.

–  Screw in support elements -A-, as illustrated on adjustment plate. Arrow symbol -B- on adjustment plate points in vehicle driving direction.

–  Place gearbox jack under vehicle. –  Align adjustment plate parallel to gearbox and lock safety support on gearbox. –  Remove lower engine/gearbox connecting bolts. –  Remove starter → Rep. Gr.27. –  Press gearbox off dowel sleeves.

–  Now swing gearbox forwards -arrow-, lower slightly and set at an angle using gearbox support -3282- so as to maintain clearance to body and subframe.

–  Then lower gearbox carefully, when doing this guide flange/bevel box -A- past support device for engine -3300 A-.

–  Lower gearbox observing subframe -arrow-. –  When lowering gearbox, change position of gearbox using spindles of gearbox support -3282-.   Note Observe power assisted steering line when lowering gearbox.