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 battery and battery tray → Electrical system; Rep. gr.27. –  Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -B-.

–  Pull gear selector cable off pin. –  Remove relay lever -A- together with cable end-piece → Chapter. –  Remove gearbox selector lever -B- by removing nut -arrow 2-.

–  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. Do not disconnect pipes.   Caution Do not operate clutch pedal any more. –  To prevent damage to vacuum hose from brake servo to engine, it must be removed from engine → Rep. gr.47.

–  Gearboxes for vehicles with start-stop system: pull connector -arrow- from gearbox neutral position sender -G701-. –  Remove earth strap at upper securing bolt for starter or at subframe.

–  Remove upper engine/gearbox connecting bolts. –  Bolt bracket -T10346- to rear of the three 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- –  Position adapter -10 - 222 A /8-: l  On upper longitudinal carrier, directly before the elevation (-arrow 1-) next to bolt (-arrow 2-) –  Connect left support eye on engine to support bracket. –  Connect 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.

–  Pull off connector -1- for reversing light switch -F4-. –  Remove nut -2- if present. –  Remove starter bolt -3- → Electrical system; Rep. gr.27. The starter can be left on the gearbox. –  Unbolt exhaust pipe from engine → Rep. gr.26.

–  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 left bracket -arrow- → Running gear, axles, steering; Rep. gr.40 to make space for engine and gearbox jack or gearbox when lowering gearbox.

–  Remove pendulum support.

–  Remove hexagon bolts -arrows 1- for left assembly mounting from gearbox mounting. –  Tilt engine/gearbox assembly by lowering it via the spindle of support bracket -10-222 A- that is connected to engine.   Note Be careful of all lines when lowering gearbox. –  Remove gearbox bracket by removing bolts -arrows 2-.

–  For vehicles with a sheet metal sump, remove cover plate near sump. –  Unbolt left securing bolt for heat shield -1- from subframe. –  Secure retainer -T10346- with bolt -2-.

-2- = 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. 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).

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