Volkswagen Workshop Service and Repair Manuals

Removing –  Remove engine cover → Rep. gr.15. –  Remove air filter → Rep. gr.24 –  Remove battery → Electrical system; Rep. gr.27.

–  Remove battery tray -arrows-. Vehicles with turbocharger:

–  Press release buttons, pull off air hose -1- and swivel to side. –  Unscrew bolt -arrow- for air pipe. –  Undo hose clip -2- and remove air pipe. –  Remove intake hose between air pipe and turbocharger. –  Seal turbocharger with the sealing plug set for engine -VAS 6122/40-. Continuation for all models: –  Place sufficient lint-free cloths in area of engine and gearbox. –  Draw off as much brake fluid as possible from brake fluid reservoir using brake filling and bleeding equipment -VAS 5234- or extraction unit -V.A.G 1869/4-. Vehicles with manual gearbox:

–  Detach supply hose -B- for clutch master cylinder, lift clear and tie in place. Continuation for all models:

–  Unclip heat shield and place to one side.

–  Disconnect connector -A- from brake fluid level warning contact. –  Unscrew brake lines -1- and -2- from brake master cylinder and seal brake lines using sealing plugs from repair kit -1H0 698 311 A-. –  Unscrew brake master cylinder nut -4-. –  Remove heat shield (if installed) -3-.

–  Separate connector -A- from brake light switch -F-. –  Unscrew nut -1- from brake master cylinder -2-. –  Carefully take brake master cylinder -2- out of brake servo.

–  Unclip lines -1- from retainer. –  Unscrew bolts -3- and place coolant expansion tank -2- to one side. –  Pull vacuum hose out of brake servo. –  Remove gear selector cable from gear stick and cable support from gearbox casing → Rep. gr.34 –  Remove noise insulation → General body repairs, exterior; Rep. gr.50. Vehicles with turbocharger:

–  Separate charge air hose for turbocharger from charge air pipe. Continuation for all models: –  Move lock carrier to service position → General body repairs, exterior; Rep. gr.50   Caution Danger of destruction due to reverse running direction in the case of a poly V-belt that has already run. Before removing the poly V-belt, use a piece of chalk or a felt pen to mark the running direction.

–  Turn tensioner in direction of -arrow- to relieve tension on poly V-belt. –  Use the adjustment pin -T10060 A- to arrest the tensioner. –  Remove poly V-belt.

–  Remove electrical connector -1- for control valve for compressor of air-conditioning system -N280-.   WARNING Danger of injury due to coolant. It is not permissible to open the coolant circuit of the air-conditioning system. –  Unscrew bolts -arrow- for air-conditioning compressor..   Caution Danger of damage to coolant lines and hoses. Do not excessively stretch coolant line and make sure they are not kinked or bent double. –  Fasten air-conditioning compressor together with connected coolant hoses to the longitudinal member above.

–  Undo nuts -arrows- of the connection between header and turbocharger. –  Place the header to one side.

–  Unscrew bolts -1- to -3- and remove pendulum support. –  Remove cable support from gearbox → Rep. gr.34

–	Fit support bracket -10 - 222 A- and support engine/gearbox assembly.

–	Mount adapter -10 - 222 A /8- on the longitudinal beams directly before the projection -arrow 1- and next to the bolt -arrow 2-.

–  Screw holder -T10346- onto the rear of the 3 mounting holes for the battery tray. –  Attach spindle -10 - 222 A /11- to holder -T10346- and tighten it in position. –  Fasten shackle -10 - 222 A /12- to gearbox casing. –  Attach spindle of support bracket -10 - 222 A- to shackle -10 - 222 A /12- and tighten it in position.

–  Unscrew bolts -arrows- of engine/gearbox support on the engine.

–  Unscrew bolts -arrows- of engine/gearbox support on gearbox.

–  Lower engine/gearbox assembly (first one side and then the other) via the spindles and pull towards the front as far as possible. On the gearbox side, the distance -a- between the gearbox brace and the gearbox support must not be more than 7 cm.

On the engine side, the distance -a- between the engine brace and the engine support must not be more than 11 cm.   Note t  Make absolutely sure that the drive shafts can move freely in relation to the engine/gearbox support. t  In order to prevent damage, it must be ensured that the drive shafts do not rest on the engine/gearbox support! –  Separate brake pedal from brake servo → Chapter.

–  Remove bolts -1- from brake servo. –  Carefully remove brake servo -2- from the vehicle.