Volkswagen Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ 10-222 A Support
• ◆ 3094 Hose clamps
• ◆ 3282 Gearbox support
• ◆ 3282/24 Adjustment plate
• ◆ 3336 Gearbox lifting beam

• ◆ 10-222 A/1 Support
• ◆ V.A.G 1331 Torque wrench
• ◆ V.A.G 1332 Torque wrench
• ◆ V.A.G 1383 A Engine/gearbox jack
• ◆ V/175 Socket

Removing gearbox

• ‒ Selector lever in "P" position.
• ‒ Remove left-hand drive shaft/wheel hub bolt.
• ‒ Remove front left wheel bolts.
• ‒ Obtain radio code on vehicles with coded radio.
• ‒ Install battery.
• ‒ Remove battery console.

Vehicles up to 06.99

• ‒ → Remove cable guide rail.

Continued for all vehicles

• ‒ Remove radiator fan control unit.
• ‒ Remove air cleaner.

Vehicles up to 06.99

• ‒ Remove selector lever cable from gearbox (29 - Corrugated locking element).

Vehicles from 07.99

• ‒ → Remove corrugated locking element -1-.

• ‒ → Lever off selector lever cable.

• ‒ → Remove selector lever cable support bracket from gearbox -arrows-.

• ‒ → Remove connector -1- from holder -2-.
• ‒ Remove holder from gearbox -arrows-.

• ‒ → Pull cable guide rail -1- out of eye -2-.

• ‒ → Pull cable guide rail -1- off engine/gearbox bolt.

• ‒ → Remove connector from holder on suspension strut turret and separate.

Continued for all vehicles

• ‒ → Clamp both ATF cooler hoses using -3094- and remove from ATF cooler.
• ‒ Remove upper engine/gearbox connecting bolts.

Vehicles from 07.99

• ‒ Remove upper starter motor bolt.

Continued for all vehicles

• ‒ → Fit support bar 10-222 A with legs 10-222 A/1 and support engine/gearbox in this position.
• ‒ Remove heat shield for front pipe.
• ‒ Disconnect Lambda probe and remove front pipe/catalyst.
• ‒ Remove ribbed V-belt cover.
• ‒ Remove front left wheel.
• ‒ Disconnect drive shafts at flanges.
• ‒ Remove left-hand drive shaft.

=> Running gear; Repair group 40; Removing and installing drive shaft

• ‒ → Remove speedometer connector -arrow-.
• ‒ Remove oil pan cover plate.

• ‒ → Remove torque converter cover plate and nuts (qty. 3) from torque converter.
• ‒ Remove pendulum support.
• ‒ Renew bolts

Vehicles up to 06.99

• ‒ → Remove pendulum support, to do this remove bolts -3- and nut -2- and take out bolt -1-.
• ‒ Renew bolts

Vehicles from 07.99

• ‒ → Remove pendulum support.
• ‒ Renew bolts

Continued for all vehicles

• ‒ Disconnect electrical connections on gearbox.

Vehicles up to 06.99

• ‒ → Remove upper right-hand assembly mounting.
• ‒ Remove ribbed V-belts, to do this lower engine/gearbox via right-hand support device spindle slightly.
• ‒ Remove ribbed V-belt pulley.
• ‒ Lower engine/gearbox via support device spindles until the left-hand assembly mounting bolts are accessible.

• ‒ → Remove left assembly mounting complete.
• ‒ Renew bolts

Vehicles from 07.99

• ‒ → Remove upper right-hand assembly mounting -1-.
• ‒ Renew bolts

• ‒ → Remove left assembly mounting complete.

Continued for all vehicles

• ‒ Remove power steering pipes from radiator.

Do not open pipework !

• ‒ Remove electrical wiring retainer on rear of engine.
• ‒ Remove fan wheel.

• ‒ → If a heat shield is fitted, remove heat shield.
• ‒ Set up gearbox mount 3282.

The gearbox mount 3282 is set up with the adjusting plate 3282/24 for removing the automatic gearbox 001.

• ‒ Move jack V.A.G 1383 A with gearbox mount 3282 under the gearbox and support gearbox.

• ‒ → Secure gearbox mounting 3282 with drilled plate to hole on gearbox -arrow-.
• ‒ Remove lower engine/gearbox connecting bolts.
• ‒ Press gearbox off engine; when doing this, press torque converter out of drive plate.
• ‒ Press torque converter against ATF pump.
• ‒ Lower engine and gearbox until the tensioning roller of the engine can be guided passed the longitudinal member.
• ‒ Lower gearbox slightly.
• ‒ Swivel gearbox and carefully lower.
• ‒ Secure torque converter to prevent it falling out.

Installing gearbox

Install in reverse order but note following:

• ‒ Installing torque convertor => Page 32-3 .

When swinging in gearbox, ensure that the torque converter does not slip out of position.

• ‒ → Before installing gearbox, ensure that the dowel sleeves are correctly located between engine and gearbox.
• ‒ When installing gearbox, observe torque converter contact impression on drive plate.
• ‒ Before tightening screws/bolts, check whether they need renewing. In particular, bolts other than those used on the gearbox often require renewal.

The bolts from assembly mountings and suspension systems are affected in most cases. Check relevant repair groups for further details.

To ensure smooth and quiet running of this Volkswagen, it is important that the engine and gearbox are installed free of tension. For information on how to do this

=> Repair group 10; Removing and installing engine

Information about torque settings of assembly mounting bolts and the exhaust system can also be found here.

• ‒ → Always renew corrugated locking element -1- of selector lever cable.
• ‒ Check selector lever cable adjustment, adjust if necessary => Page 37-29 .
• ‒ Checking multi-function switch adjustment and adjust if necessary.

=> Self-diagnosis for automatic gearbox 001; Repair group 01; Performing self-diagnosis; Adjusting multi-function switch

• ‒ Perform self-diagnosis and initiate basic setting.

=> Self-diagnosis for automatic gearbox 001; Repair group 01; Performing self-diagnosis; Initiating basic setting

• ‒ Enter radio code.

=> Radio, Telephone, Navigation; Repair group 91; Radio systems

• ‒ Check and top up ATF level .
• ‒ Check all electrical connections; cover/seal must prevent ingress of moisture (visual check).

Tightening torques

Left-hand console for assembly mounting to gearbox 25 Nm

→ Gearbox to engine

→ Torque converter to drive plate 85 Nm

Torque settings for running gear:

Driveshaft to flanged shaft, swivel joint to wishbone, coupling rod to wishbone, assembly mounting including pendulum support

=> Running gear; Repair group 40

Wheel bolts

=> Running gear; Repair group 44; Wheel bolt torque settings

Steering

=> Running gear; Repair group 48

Engine torque settings:

=> Repair group 10; Removing and installing engine

Transporting the automatic gearbox

Special tool 3336 may be used to transport the automatic gearbox and also when setting up gearbox mount 3282.

• ‒ → Secure special tool 3336 to gearbox housing flange.
• ‒ Position pins so that 10 holes are visible in chain direction.