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. –  If the lifting eyes of the engine for support bracket -10 - 222 A- are covered by a component, for example the air filter, it must be removed now. → Rep. gr.23 or → Rep. gr.24. –  Remove complete air filter housing if it is near battery → Rep. gr.23 or → Rep. gr.24. –  Remove battery, battery cover and battery tray → Electrical system; Rep. gr.27. –  Release end-piece from gate selector cable → Chapter. –  Pull clip -arrow 1- off and remove relay lever together with cable end-piece. –  Remove securing clip -arrow 2- for gear selector cable from gearbox selector lever -A-.

–  Pull gear selector cable off pin. –  Remove gearbox selector lever -A- by removing nut -arrow 3-.

–  Remove cable support bracket from gearbox -arrows-. –  Then raise and secure gear selector cable and gate selector cable. –  Remove retainer -B- from gearbox and pull it off pipe/hose line -A-.

–  Then remove gearbox support -arrow A-. –  Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes.   Caution Do not operate clutch pedal any more. –  Remove earth strap from top starter bolt.

–  Pull connector -arrow 1- off reversing light switch -F4-. –  Now remove connector -arrow 2- and wire -arrow 3- from starter. –  Then remove upper securing bolt on starter.

–  Remove upper engine/gearbox connecting bolts. –  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. –  Remove both foam pieces from upper edge of left and right wings → Body, front; Rep. gr.50. –  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 carrier, directly before the elevation (-arrow 1-) next to bolt (-arrow 2-) –  Connect engine and bracket -T10346- to support bracket. –  Take up weight of engine/gearbox assembly and support bracket 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. –  If front vehicle level sender -G78- is present, unbolt it from transverse link → Rep. gr.40. –  Remove left coupling rod from anti-roll bar and lay to side → Running gear, axles, steering; Rep. gr.40.

–  Gearboxes for vehicles with start-stop system: pull connector -arrow- from gearbox neutral position sender -G701-. –  Remove bracket from starter. –  Remove starter → Electrical system; Rep. gr.27. –  Remove left charge air hose -arrow 1- and -arrow 2- and charge air pipe from engine → Rep. gr.21.

–  Remove right charge air hose -arrow 2- → Rep. gr.21

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

–  Disconnect front exhaust pipe from turbocharger (-arrow-) → Rep. gr.26 and secure it.

–  Remove pendulum support.

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

–  Remove drive shaft heat shield, if present -arrows- → Running gear, axles, steering; Rep. gr.40. –  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 hexagon bolts -arrows- for left assembly mounting from gearbox mounting. –  Lower gearbox by adjusting spindle attached to engine. l  Securing bolts -arrows- for gearbox bracket -A- must be accessible.

–  Remove gearbox bracket -A--arrows-.

–  If present, unbolt heat shield for power steering control unit -J500- from subframe, -arrows-. –  Attach bracket -T10346- with bolt -1- to left threaded hole in subframe. -1- = Flange bolt M6 x 20 –  Secure engine support -3300 A- to bracket -T10346-.

–  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 for coolant.   Note Observe connecting lines, hoses and radiator when moving engine/gearbox assembly. To remove gearbox „02S“, set up gearbox support -3282- with adjustment plate -3282/39-. –  Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383A-. –  Align arms of gearbox support according to holes in adjustment plate.

–  Screw in support elements-A - and -C- on adjustment plate as shown. –  Position engine and 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. –  Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

–  Remove remaining bolts -5 and 6- from gearbox connection on engine.

–  Press gearbox off dowel sleeves and carefully swing towards subframe.

Then the right flange shaft -1- must be guided past the notch -arrow- in the intermediate plate. –  Tilt gearbox further using spindles of gearbox support -3282-. l  Differential must face upwards. l  Swing gearbox down near 6th gear.

–  Guide gearbox with differential over subframe -A- and swing out. –  When lowering gearbox, change position of gearbox using spindles of gearbox support -3282-.   Note Be careful of all lines when lowering gearbox.