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 engine cover.
• ‒ 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.
• ‒ Pull off/disconnect all other electrical connections as necessary from engine and lay to one side.

Vehicles with accelerator cable

• ‒ Unclip accelerator cable from air cleaner upper part.
• ‒ Detach the accelerator cable from the support bracket and the throttle valve control part (do not remove locating clip).

Continuation for all vehicles

• ‒ Remove air cleaner together with air intake connecting piece:

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

• ‒ Disconnect fuel supply and fuel return pipes at fuel rail.

• ‒ Pull vacuum and breather hoses off engine.

• ‒ Pull connectors off thermo-switch and radiator fan.
• ‒ Remove noise insulation tray.
• ‒ Separate front exhaust pipe from exhaust manifold , exhaust manifold, front exhaust pipe and catalyst with attachments.

• ‒ → Unbolt pendulum support from gearbox -arrow-.

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 19-11 .
• ‒ 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 13-11 .
• ‒ Unbolt power steering vane pump and secure to sub-frame with wire; hoses remain connected:

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

• ‒ Remove power steering reservoir and tie up.
• ‒ Unclip P.A.S. pressure hose/pipe from securing clamp.

Vehicles with air conditioner

• ‒ Removing air conditioner compressor:
• ‒ Observe additional information and removal instructions =>Page10-17

Continuation for all vehicles

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

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

• ‒ Removing lock carrier with attachments:

=> General body repairs; Repair group 50; Body, front; Removing and installing lock carrier with attachments.

Vehicles with manual gearbox

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

     Pulley end:
     3rd hole in hook at position 1

     Flywheel end:
     3rd 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 with bracket 3180 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.
• ‒ 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.