Volkswagen Workshop Service and Repair Manuals

Removal –  Disconnect battery → Electrical system; Rep. Gr.27.   Note t  Check if the vehicle has a code radio. If positive, request the anti-theft code before disconnecting the battery earth strap. t  When the battery is reconnected, check the vehicle's equipment (radio, clock, electric door locks, power windows, etc.) according to the repair manual and/or instructions of use. –  Remove the battery support. –  When the air filter is installed behind the battery, also remove the → Engine; Rep. Gr.24.

–  Remove the safety mechanism of the cable fastening elements, towards -arrow 1- to the stop, and lock them by turning to the left, towards -arrow 2-. –  Remove circlip -arrow 3- from inversion lever -A- and remove lever. –  Loosen nut -arrow 4- and remove the transmission selector lever -B-.

–  Remove the cable fastening supports -arrows-. –  Remove tubing and hose assembly -A- from bracket -B- located on transmission. –  Remove the slave cylinder on the hydraulic drive -C- without opening the tubing, and fasten it.   Note Do not press the clutch pedal. –  Remove earth strap from the upper fastening screw on the engine/transmission. –  Loosen upper screws fastening the engine to transmission. –  Loosen upper fastening screw on the starter. Vehicles with petrol engines

–  Install Bracket or VW 061 -10-222A- with Support -10-222 A/1- and sustain slightly the engine/transmission. Vehicles with diesel engine

–  Install Bracket or VW 061 -10-222A- with Support -10-222 A/1- and Additional hook -10-222 A/2- Continued for all vehicles.   Note If necessary, use the lifting eyes -030 103 390 F-(on pulley side), -030 103 390 G-(on inertial flywheel side). –  Relieve the engine/transmission assembly weight through the spindles. –  Loosen left front wheel screws. –  Lift the vehicle. –  Remove the left front wheel. –  Remove noise insulation and left wheel case protection → General body repairs, exterior; Rep. Gr.66.

–  Disengage connector -1- for reverse gear lights. –  Remove cable support -2- on starter -arrow-. –  Remove starter → Electrical system; Rep. Gr.27. –  Remove connectors' bracket. –  Remove front exhaust system → Engine; Rep. Gr.26.

–  Remove pendulum support -arrows A- and -arrows B-.

–  If applicable, remove the protective cap from the drive semi-shaft, removing screws -arrows-. –  Remove drive semi-shaft from transmission propelling flanges → Running gear, axles, steering; Rep. Gr.40. When doing this, take care to prevent damages on the flange protective plate.

–  Check the existence of cover plate -A- over the right drive shaft and remove it -arrows-. –  Mark the installation position of the screws that fasten the lower articulation of the suspension's left wishbone.

–  Loosen the screws -arrows-. –  If applicable, release the wishbone from the left coupling bar -1-. –  Move the wheel bearing case outwards. –  Remove the drive semi-shaft through the clearance between the subframe and transmission. –  Place the drive semi-shaft upwards and fasten it with wire on the suspension pillar.

–  Disengage the connector from the speedometer command transmitter -arrow-.

–  Remove intake manifold brackets -arrow-, if applicable. –  Loosen screw -A- fastening the engine to transmission by over the right propelling flange.

–  Loosen hex screws -arrows- on engine left bracket. –  Tilt carefully the engine/transmission assembly. To do that, turn the two screws on the Bracket or VW 061 -10-222A- by approximately 90 mm downwards.   Note When lowering the engine, make sure the differential is not supported by the subframe. l  It should be possible accessing the screws -arrows- that fasten the console -A-.

–  Remove console -A--arrows-. –  Loosen lower screws that fasten the engine to transmission (without removing them from engine). –  Install Bracket -3282- with Adjustment plate -3282/31- to remove 02T transmission. –  Install the transmission support assembly arms aligned with the adjustment plate holes.

The symbols -A- on the Adjustment plate -3282/31- show the supports required, and arrow -B- indicates run direction.

–  Place Transmission or engine + transmission set jack or EQ 7081 -VAG 1383A- under transmission. –  Align the adjustment plate and engage safety bracket in transmission. –  Fasten transmission to Bracket -3282- –  Loosen screw that fastens the engine to transmission -arrow-.

–  In vehicles equipped with oil crankcase over plate, a cover plate must be dismounted -arrows- in the engine crankcase region. –  Separate transmission from engine and turn it carefully towards subframe. –  Press the engine outwards, carefully, with the help from a second mechanic. –  Take care of the radiator during this operation. –  Turn the transmission downwards by the differential region.

–  Next, lower carefully the transmission by passing the right propelling flange -A- close to the flywheel/intermediate plate, and the left propelling flange -B- close to the subframe. –  When lowering, change the transmission position by the spindle of the Transmission or engine + transmission set jack or EQ 7081 -VAG 1383A-.