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. –  Remove cover, if necessary with air filter, from engine.   Note Air filter → Rep. Gr.24 Remove air filter if fitted on left in engine compartment:

–  Remove intake hose -1-, connector -2- and hose -3- from air mass meter. –  Then remove bolts -4- and -5-. –  Remove complete air filter → Rep. Gr.24. Through gearbox date 02 08 8

–  Pull off connector for reversing light -arrow-. From gearbox date 03 08 9

–  Pull off reversing light connector -arrow 3-. Vehicles with 1.4 l engine –  Remove retainer for lambda probe -arrow 1- by removing securing bolt -arrow 2-. Continuation for all vehicles

–  Remove front gear selector rod -1- from gearbox selector lever -2-. –  Then remove securing clip -3-. –  Pull intermediate lever -4- off bracket. –  Turn intermediate lever -4- and pull it off selector rod -5-.

–  Then lever off both coupling rods -arrows-. –  Unbolt gearbox selector lever -1- from gearbox. –  Now remove the two bolts -2- for gearbox bracket -3- from gearbox. –  Remove bracket together with coupling rods and gearbox selector lever.

–  Now remove slave cylinder -arrows- and raise. Secure with wire and do not disconnect pipes.   Note Do not depress clutch pedal.

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

–  Fit support bracket -10 - 222 A- together with racks -10 - 222 A/1-. –  Take up weight of engine/gearbox assembly on spindles.

–  Remove retainer for power steering line from rear bolt of gearbox bracket -arrow 1-. –  Remove assembly mounting hexagon bolts -arrows 2- from gearbox mounting. –  Remove gearbox bracket -arrows 3- and -arrow 1-. –  Pull connector off road speed sender -arrow 4-. –  Disconnect all other electrical connections and earth wires from gearbox and from the engine/gearbox securing bolts. –  If insulation tray is installed below engine and gearbox, remove it. → General body repairs, exterior; Rep. Gr.50. –  Remove starter → Electrical system; Rep. Gr.27.

–  If shield for right inner constant velocity joint is installed, remove it -arrows-. → Running gear, axles, steering; Rep. Gr.40. –  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.

–  Remove small cover plate for flywheel -A- behind right-hand flange shaft -arrows-, if fitted. –  Remove large cover plate for clutch, if fitted. –  Separate exhaust system → Rep. Gr.26.

–  Remove pendulum support -arrows A- and -arrows B-. –  Lower engine/gearbox assembly slightly using left spindle. –  Assemble gearbox jack with gearbox support -3282-, adjustment plate -3282/5- for “020” gearbox and support elements as follows: –  Fit adjustment plate -3282/5- on gearbox support -3282- (adjustment plate fits in only one position). –  Align arms of gearbox support according to holes in adjustment plate.

–  Screw in support elements -A- as illustrated on adjustment plate.

–  Position gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel. –  Align adjustment plate parallel to gearbox and lock safety support on gearbox. –  Remove lower engine/gearbox connecting bolts.

–  Bolt support rail -VW 457/1- to subframe at securing holes for pendulum support. –  Spacers totalling 6 mm must be inserted between subframe and support rail -VW 457/1-. A -  2 hexagon bolts M 8 x 25 –  Fit support -3300 A- and bolt on -arrows-. Vehicles with a 1.4 l engine

–  Fit support -3300 A- on engine between gearbox and exhaust pipe. Continuation for all vehicles –  Carefully press engine and gearbox forwards.   Note Do not damage P.A.S. line when moving engine/gearbox assembly.

–  Press gearbox off dowel sleeves and carefully swing towards subframe. –  Lower gearbox slightly and tilt via spindles of gearbox support -3282-.

–  Then lower gearbox carefully, guiding with right flange shaft -A- in area of flywheel as shown and with left flange shaft -B- in area of subframe. –  When lowering gearbox, change position of gearbox using spindles of gearbox support -3282-.   Note Observe power assisted steering line when lowering gearbox.