Volkswagen Workshop Service and Repair Manuals

Remove –  First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding. –  Remove the whole housing of the air filter → Rep. Gr.24. –  Remove battery and battery console → Rep. Gr.27. –  Remove the engine cover.

–  Secure locking mechanism on gear selector cable and gate selector cable by pulling forwards until stop -arrow 1- and then turning to left to lock -arrow 2-. –  Remove circlip -arrow 3- off relay lever -A- and remove inversion lever. –  Remove selector lever -B- by removing nut -arrow 4-

–  Remove cable support bracket from gearbox -arrows-. –  Then tie gear selector cable and gate selector cable up. –  Remove bracket -B- from gearbox and pull it off the pipe/hose assembly -A-.

–  Remove slave cylinder -arrows-, place to one side and secure with wire. Do not disconnect pipes.   Note Do not depress clutch pedal –  Remove upper securing bolt from engine/gearbox earth strap.

–  Remove connector -arrow 1- from starter. –  Remove protective cap -arrow 2- from starter. –  Remove cable from starter. –  Pull off reverse light connector -arrow 3-. –  Then remove upper securing bolt on starter. –  Remove engine/gearbox upper securing bolts.

–  Pull connector off speedometer sender -arrow-. –  Remove, in case there are, hoses and cables connected in the area of the grommets of the motor mounting for theHolding device -10-222A-.

–  InstallHolding device -10-222A- together with mountings -10-222A/1- and the adpaters-10-222A/3-.

–  Secure additional hook -10-222A/2- in the left inferior part of the motor. –  Connect additional hook -10-222A/2- to the device. –  Alliviate the weight of the motor/gearbox set through the spindles of the holding device. –  Remove front left wheel bolts. –  Raise vehicle. –  Remove left wheel. –  Remove noise insulation tray and front left wheel housing liner → Rep. Gr.66. –  Remove starter → Rep. Gr.27. –  Remove cable from gearbox. –  Loosen doble sleeve of the exhaust system that is located after the front exhaust pipe → Rep. Gr.26. –  Tie up exhaust pipe to body in area of catalyst using wire

–  Remove support -arrows A and B-. –  Remove right hand inner constant velocity joint protective gaiter from engine if fitted. –  Remove drive shafts from gearbox flanged shafts. –  Raise left drive shaft and secure.

–  Mark installation position of bolts -setas- for left swivel joint. –  Remove bolts -arrows- → Rep. Gr. 40 –  If fitted, remove connecting bar -1- from the anti-roll bar → Rep. Gr.40 –  Swing wheel bearing housing outwards. –  Pull left-hand drive shaft out between sub-frame and gearbox. –  When doing this, guide drive shaft into wheel housing and tie to suspension strut using wire. –  Remove locking mechanisms from the right side of the engine → Rep. Gr.10.

–  Remove hexagon bolts -arrows- of left-hand support bracket mounting from gearbox.

–  Unbolt gearbox mounting from body (-arrows A, B and C-). –  Incline the engine/gearbox assembly by lowering it via left spindle of support bar -10-222A-   Note When lowering the engine/gearbox assembly, ensure gearbox does not come into contact with the subframe in the differential area. l  The gearbox console -A- securing bolts (arrows) must be accessible.

–  Remove gearbox console -A--arrow-.

–  Remove flywheel small cover plate -A- behind the right side flanged shaft -arrows-, if fitted. –  Assemble jack for engine and gearbox with the Removal device -3282-, adjustment plate -T30020- for “02R” gearbox and housing elements, as follows: –  Install the adjustment plate -T30020- onto the Removal device -3282-. (The adjustment plate has only one position of assembly). –  Align arms of gearbox support according to holes in adjustment plate.

–  Bolt on support elements -A- as illustrated on adjustment plate.

–  Install jack for engine and gearbox below the vehichel, -arrow B- on the adjustment plate pointing towards the front of the vehicle. –  Align adjustment plate parallel to gearbox and lock safety supports on gearbox. –  Remove lower engine/gearbox securing bolts.

–  Press gearbox off dowels and carefully swing towards subframe.

–  Carefully lower the gearbox. Guide right-hand flanged shaft -A- in area of flywheel/intermediate plate as illustrated and guide left side flanged shaft -B- in area of subframe. –  Lower gearbox in area of differential towards subframe. –  When lowering the gearbox change position of gearbox using the Removal device - 3282- spindle.   Note Take note of coolant pipe between engine and heat exchanger for heating system. Transporting the gearbox

–  Install Holding device -3336- into clutch body.

–  Set support beam on sliding piece with locking pin -arrow-. No. of holes visible = 5 –  Lift gearbox with workshop crane and Holding device -3336 -. –  Place gearbox, for example onto transport container.