Volkswagen Workshop Service and Repair Manuals

Note:

Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap must be disconnected. Obtain radio code first if necessary.

• ‒ The engine is removed forwards together with the gearbox.
• ‒ With ignition switched off disconnect battery earth strap.
• ‒ All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
• ‒ Remove air cleaner:

=> Repair group 24; Servicing injection; Dismantling and assembling air cleaner

• ‒ Remove battery and battery retainer.
• ‒ Open and close the expansion tank sealing cap to release pressure in cooling system.
• ‒ Disconnect all electric wires from gearbox, alternator and starter and move clear.

• ‒ Loosen or separate the following components:
• ‒ The hose from intake manifold to activated charcoal filter system
• ‒ The vacuum hose from inlet manifold at brake servo
• ‒ The connector from coolant temperature sender and oil pressure switch
• ‒ The collective connectors below the thermostat housing
• ‒ The ignition transformer and Hall sender connectors
• ‒ The engine speed sender connector
• ‒ Lambda probe connector in exhaust manifold
• ‒ The 2-pin connector from knock sensor (rear of cylinder block)
• ‒ The road speed sender connector
• ‒ The reversing light connector

• ‒ Now separate fuel supply as well as fuel return pipes at connecting point on suspension strut turret.
• ‒ Pull off/disconnect all other electrical connections as necessary from engine and lay to one side.
• ‒ Separate front exhaust pipe from exhaust manifold , exhaust manifold, front exhaust pipe and catalyst with attachments.

• ‒ → Unbolt pendulum support at gearbox housing.

Vehicles with manual gearbox

• ‒ Disconnect clutch cable:

=> Repair group 30; Servicing hydraulic clutch control

• ‒ Disconnect selector mechanism from gearbox.

=> Repair group 34; Servicing gear change mechanism

Vehicles with automatic gearbox

• ‒ Remove selector lever cable from gearbox:

=> Repair group 37; Servicing selector mechanism; Dismantling and assembling selector mechanism

Continuation for all vehicles

• ‒ Drain coolant => Page 19-10 .
• ‒ Loosen hose clips and pull coolant hoses off coolant thermostat housing.
• ‒ Loosen belt pulley securing bolts from power steering vane pump.
• ‒ Remove ribbed belt => Page 13-9 .
• ‒ Unbolt power steering vane pump and secure to sub-frame with wire; hoses remain connected:

=> Running gear, axles, steering; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic lines; Removing and installing power steering vane pump.

• ‒ Remove securing clamps for power steering pressure pipe.

Vehicles with air conditioner

• ‒ Removing air conditioner compressor:
• ‒ Observe additional information and removal instructions =>Page10-18

Continuation for all vehicles

• ‒ Remove left and right-hand drive shaft on gearbox and tie up:

=> Running gear, axles, steering; Repair group 40; Servicing front suspension; Removing and installing drive shafts

• ‒ Removing lock carrier with attachments:

=> General body repairs exterior; Repair group 50; Body front; Assembly overview

Vehicles with manual gearbox

• ‒ → Attach lifting tackle 2024 A as follows and lift slightly with workshop crane:

     Pulley end:
     2nd hole in hook at position 1

     Flywheel end:
     2nd hole in hook at position 5

Notes:

• ◆ The positions marked 1...4 on the bar must be towards the pulley end.
• ◆ The holes in the hook rails are counted up from the hook.

Vehicles with automatic gearbox

• ‒ → Attach lifting tackle 2024 A as follows and lift slightly with workshop crane:

• Pulley end:
  4th hole in hook at position 1

     Flywheel end:
     1st hole in hook at position 5

Notes:

• ◆ The positions marked 1...4 on the bar must be towards the pulley end.
• ◆ The holes in the hook rails are counted up from the hook.

Vehicles with manual gearbox

• ‒ → Unbolt assembly at gearbox and engine mountings -arrows-.

Vehicles with automatic gearbox

• ‒ → Unbolt assembly at gearbox and engine mountings -arrows-.
• ‒ Remove gearbox mounting -arrows-.

Continuation for all vehicles

• ‒ Lower assembly until it is released from the gearbox mounting.
• ‒ Pull assembly out forwards. When doing this, if necessary turn assembly and lower slightly.

Note:

When the assembly is lifted off, it must be carefully guided to prevent damage to the bodywork.