Volkswagen Workshop Service and Repair Manuals

Removing gearbox –  Remove gearbox together with bevel box. –  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. At a later point, the support bracket -10-222 A- will be connected to the lifting eyes of engine. –  If engine cover blocks access, remove engine cover. –  Remove complete air filter housing if it is located close to the battery. → Rep. gr.23 or → Rep. gr.24

–  Remove battery and battery tray → Electrical system; Rep. gr.27. –  Remove lines -A- from bracket -B-.

–  Remove securing clip -1- for gear selector cable from gearbox selector lever -2- and pull cable off pin -arrow-.

–  Releasing cable end-piece from gate selector cable l  To avoid damage to gate selector cable, separate cable end-piece from gate selector cable before removal. –  Pull locking mechanism forward to stop in -direction of arrow 1- and then lock by turning to left in -direction of arrow 2-. –  Then push relay lever forwards (-in direction of arrow 3-). –  The relay lever is removed together with the cable end-piece at a later point.

–  Remove cable support bracket from gearbox -arrows-, lay to side and secure with wire.

Vehicles with pipeline between master and slave cylinder –  Clamp off supply hose to master cylinder using hose clamp -3094-.

Vehicles with pipe/hose assembly between master and slave cylinder –  Clamp off hose of pipe/hose line -A- to slave cylinder using hose clamp -3094-. Continuation for all –  Pull out clip -arrow- for pipe/hose line or pipeline to stop. –  Pull pipe/hose line or pipeline out from slave cylinder bleeder and seal.   Caution Do not operate clutch pedal any more. –  Remove connector and wire from starter.

–  Remove upper engine/gearbox connecting bolts -arrows-. The bolt heads might differ from those shown in the diagram. –  Then remove upper securing bolt on starter.

–  Bolt bracket -T10346- to rear of the 3 mounting holes for battery tray. –  To do this, use a collar bolt M 6 x 80 or a securing bolt for battery tray. –  If there are hose and cable connections in area of engine support eye for support bracket -10-222 A-, remove these now.

–  Set up support bracket -10-222 A- in front of bonnet support. –  Use: t  Adapter -10-222 A /3- t  Adapter -10-222 A /8- t  Adapter -10-222 A /18- –  Position adapter -10-222 A /8-: l  on upper longitudinal members, l  directly in front of protrusion (-arrow 1-), l  next to bolt (-arrow 2-). –  Connect bracket -T10346- to support bracket. –  Attach spindles in left engine support eyes. –  Take up weight of engine/gearbox assembly and support bracket on spindles.

The front drive shafts will be removed at a later stage. –  With vehicle standing on its wheels, loosen collar bolts -arrow- no more than 90°; otherwise wheel bearing will be damaged → Running gear, axles, steering; Rep. gr.40. –  Raise vehicle. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50. –  Remove lower part of front right and left wheel housing liner → General body repairs, exterior; Rep. gr.66. –  Remove nuts -1- and remove retainer with electrical connections from lower starter bolt. –  Remove starter → Electrical system; Rep. gr.27.

–  Separate electrical connector -2- for reversing light switch -F4-.

–  Remove left charge air hose -arrow 1- and -arrow 2- → Rep. gr.21. –  Remove right charge air hose from charge air cooler → Rep. gr.21.

–  Remove cowling -arrow- together with radiator fans → Rep. gr.19.

–  Remove pendulum support.

–  Pull connector -1- off oil level and oil temperature sender -G266-.

–  If front vehicle level senders -G78- are present, unbolt them from transverse links → Rep. gr.40.

–  Remove drive shaft heat shield, if present, from bevel box (-arrows-) → Running gear, axles, steering; Rep. gr.40.

–  To gain more clearance in vehicles with auxiliary heaters, remove coolant hoses -1- and -2- for auxiliary heater from engine. Do not open fluid circuit → Auxiliary heating; Rep. gr.82. –  Remove front drive shafts → Running gear, axles, steering; Rep. gr.40.

–  Remove particulate filter -A- from top of engine -arrow 1- and from bottom of engine -arrow 2- → Rep. gr.26. –  Remove particulate filter - A- from bottom of engine → Rep. gr.26

–  Secure it to front wall of plenum chamber. –  Remove bolts -1- for gearbox carrier on bevel box. –  Remove bolts -2- for gearbox carrier on engine.

Vehicles with pressure unit from 11. 09 -arrow 1- From 11.09 there is a »shoulder«-arrow 2- beneath pressure unit -arrow 1- in upper area of gearbox carrier (gradual introduction). –  Loosen bolts -A- for gearbox carrier on engine. –  Remove bolts -B- for gearbox carrier on bevel box. Continuation for all

–  Mark position of propshaft with flexible coupling relative to bevel box flange with paint. –  Unbolt propshaft from bevel box -arrows- → Rep. gr.39. –  Push front propshaft back to stop. –  Unbolt earth strap from left engine/gearbox mounting.

–  Remove bolts -arrows- from left engine/gearbox mounting.

–  Lower gearbox by adjusting spindles connected to engine. Dimension -a- = about 60 mm   Note When moving engine and gearbox assembly, observe coolant hoses between engine and heat exchanger, being careful not to stretch them.

–  Unbolt bracket from gearbox -arrows-. –  Remove relay lever together with cable end-piece → Chapter. –  Remove gearbox selector lever from selector shaft.

–  Remove engine/gearbox connecting bolts -arrow- next to bevel box -A-.

–  Loosen engine/gearbox connecting bolts -2- and -3- and leave them installed just hand-tight. –  Secure brackets -T10346/1- and -T10346- with bolt -1- at bottom of subframe.

–  To do this, use middle threaded hole that is used for attaching noise insulation cover. -1- = Flange bolt M6 x 20 or flange bolt M8 x 20. –  Secure engine support -3300 A- to brackets. –  Place a cloth between engine support -3300 A- and oil pan.

–  Press engine forwards using spindle of engine support -3300 A-. In the process, observe the following points in particular: l  The air conditioning compressor -2- must not contact -arrow- the refrigerant line -1-. l  The alternator must not contact the refrigerant line. l  The pressure pipe must not contact the radiator.

To remove gearbox „02Q four-wheel drive“, set up gearbox support -3282- with adjustment plate -3282/62-. –  Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383 A-. –  Align arms of gearbox support according to holes in adjustment plate. –  Attach support elements-A- to adjustment plate as illustrated.

l  Due to the positioning of the gearbox support, arm -A- is »shorter« than arm -B-. l  The support with pin -3282/29- must be secured on arm -A- (»shorter« arm). l  This will make it easier for the »shorter« arm to be guided past the support device-arrow- at a later stage. –  Position engine and gearbox jack -V.A.G 1383 A- under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel. –  Align adjustment plate and gearbox parallel to one another. –  Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

–  Secure adapter -VW 771/40- in threaded hole of gearbox housing as shown in figure. –  Secure gearbox to gearbox support -3282- using bolt (M10x20) -A-. Pin -B- must lie flush with guide from gearbox support -3282- at bottom -arrow-.

–  Remove last engine/gearbox connecting bolt -3-. –  Press gearbox off engine towards front end.

–  Guide bevel box past cover plate -A- and gearbox carrier -B-, if necessary.

l  The exhaust gas recirculation valve -N18--arrow- and surrounding parts must not be damaged.

–  Observe longitudinal carrier -arrow 1- and subframe -arrow 2-.

–  Carefully lower gearbox, observing subframe and engine support -3300 A--arrow-.   Note Be careful of all lines when lowering gearbox.