Volkswagen Workshop Service and Repair Manuals

Removing gearbox –  First 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. –  If the lifting eyes of the engine for support bracket -10 - 222 A- are blocked by the cover or the air filter, it must be removed now. → Rep. gr.23 or → Rep. gr.24 –  Remove complete air filter housing if it is over the gearbox → Rep. gr.23 or → Rep. gr.24

–  Remove camshaft housing cover if lifting eye -arrow- is not accessible → Rep. gr.15. –  Remove battery and battery tray → Electrical system; Rep. gr.27. –  Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

–  Pull gear selector cable off pin. Metal relay lever –  Remove securing clip -arrow 2- for gate selector cable from relay lever -B-. –  Pull gate selector cable from pin. –  Pull securing clip -arrow 3- off relay lever -B- and remove relay lever. Plastic relay lever –  Remove relay lever together with cable end-piece → Chapter. Continuation for all –  Remove gearbox selector lever -A- by removing nut -arrow 4-.

–  Remove cable support bracket from gearbox -arrows-. –  Then raise and secure gear selector cable and gate selector cable.

–  Pull line between master and slave cylinders -A- out of support -B-, if present, on gearbox. –  Remove slave cylinder -arrows-, lay to side and secure with wire. Do not disconnect pipes.   Note Do not depress clutch pedal. –  Remove earth strap at upper engine/gearbox connecting bolt. –  Remove upper engine/gearbox connecting bolts. –  Then remove upper securing bolt on starter. –  If there are hose and cable connections in area of engine support eye for support bracket -10 - 222 A-, remove these now. –  Remove both foam pieces from upper edge of left and right wings → Body, front; Rep. gr.50.

–  Set up support bracket -10 - 222 A- together with adapters -10 - 222 A /8- in front of support for bonnet. –  Take up weight of engine/gearbox assembly on spindles. –  Raise vehicle. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50. –  Remove lower part of front left wheel housing liner → General body repairs, exterior; Rep. gr.66.

–  Pull off connector -1- for reversing light switch -F4-. –  Remove nut -2- if present. –  Remove starter (bolt -3-) → Electrical system; Rep. gr.27.

–  Separate exhaust system -arrows 1- and remove exhaust pipe bracket from subframe -arrows 2- → Rep. gr.26.

–  Pull connector -1- off oil level and oil temperature sender -G266-. –  Remove drive shafts from flange shafts, raise as high as possible and secure. Do not damage the surface protection → Running gear, axles, steering; Rep. gr.40.

–  Remove engine/gearbox connecting bolt -A- above right flange shaft.

–  Remove pendulum support -arrows A-, -B- and -C-.

–  Remove hexagon bolts -arrows 1- for left assembly mounting from gearbox mounting. –  Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10-222 A-. –  Remove gearbox bracket by removing bolts -arrows 2-. To remove gearbox „0AJ“, set up gearbox support -3282- with adjustment plate -3282/31-. –  Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383 A-. –  Fit adjustment plate -3282/31- on gearbox support -3282- (adjustment plate fits in only one position). –  Align arms of gearbox support according to holes in adjustment plate.

–  Attach support elements-A- to adjustment plate as illustrated. –  Screw in support hook -3282/49- instead of support element-C-. –  Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.

–  Align adjustment plate parallel to gearbox.

–  Insert support hook -3282/49- in one of the recesses in differential below flange shaft -arrow-. –  Remove engine/gearbox connecting bolt (-arrow- in previous figure). –  Disconnect wire to lambda probe → Rep. gr.21 –  Remove lambda probe wire from wire guides → Rep. gr.21.

–  Separate exhaust system so that lower bolts -arrows- may be removed. –  Have a second mechanic press engine forwards. –  Press gearbox off dowel sleeves.

–  Press gearbox with 6th gear cover towards front -arrow 1- and turn it downwards slightly -arrow 2-. –  Observe intermediate plate on engine.

–  Then carefully guide gearbox with right flange shaft -A- past flywheel -B- and intermediate plate as shown.

–  Carefully guide left flange shaft -A- past subframe bracket -B- as shown. –  Lower gearbox being careful of subframe. –  When lowering gearbox, change position of gearbox using spindles of gearbox support -3282-.   Note Be careful of all lines when lowering gearbox. –  When lowering gearbox, change position of gearbox using spindles of gearbox support -3282-.