VOLKSWAGEN GOLF 2009 (03) PDF Document

To ensure flawless and successful gearbox repairs for the VOLKSWAGEN GOLF 2009 manual gearbox, the greatest care and cleanliness, as well as the use of good and proper tools, are essential. The basic rules for safety also apply during repair work.

Before installing an oil seal, half-fill the space between the sealing lips with sealing grease -G 052 128 A1-.

The open side of the oil seal faces the side with fluid filling.

After installing, check the oil level.

Lightly oil O-rings before installing; this prevents the rings from being crushed when inserted.

Thoroughly clean parting surfaces and apply sealant -AMV 188 200 03-.

Apply sealant uniformly but not too thick.

Thoroughly clean housing joint surfaces before applying sealing paste.

Evenly apply a thin coat of sealing paste -AMV 188 200 03-.

Breather holes must remain free of sealing paste.

Renew retaining rings.

Do not overstretch retaining rings.

Retaining rings must locate properly in grooves.

Renew spring pins. Installation position: slot must be in line with direction of force.

Renew bolts for crash bar.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery.

Push driver seat as far back as possible and put steering wheel in highest position.

Remove trim and cover below trim on drive side.

Remove bracket for knee airbag together with crash bar.

Remove cable guide -2- from steering column.

Remove footwell vent -3-.

Release tool -T10178-.

Torque wrench -V.A.G 1331-.

Install crash bar -1- and tighten the 2 bolts to specified torque.

Mount cable guide -2- on steering column.

Install foot well vent -3-.

Install bracket for knee airbag together with crash bar.

Install trim and cover below trim on drive side.

If disconnected, connect battery.

Renew bolt for crash bar.

Pliers -T10005-.

Release tool -T10178-.

Torque wrench -V.A.G 1331-.

Renew bolt for crash bar.

The torque setting for the Clutch pedal to mounting bracket is 25 Nm, and self-locking nuts must be renewed.

Pliers -T10005-.

Release tool -T10178-.

Torque wrench -V.A.G 1331-.

When reconnecting the battery, refer to Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery.

Push driver seat as far back as possible and put steering wheel in highest position.

Remove trim and cover below trim on drive side.

Remove bracket for knee airbag.

Remove cable guide -2- from steering column.

Remove footwell vent -3-.

Remove crash bar -1- (bolt -2-).

If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.

To do this, remove lock washers -A- for damping.

Pull off damping.

Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.

Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-.

Swing clutch pedal forward slightly and remove over-centre spring -4- from mounting bracket.

Release clutch pedal from master cylinder with pliers -T10005-.

Remove clutch pedal.

Install in the reverse order of removal, observing the following:

Renew self-locking nuts.

Attach retainer -2- to master cylinder operating rod -1-.

Press retainer into notch in clutch pedal -3- until it can be heard to engage.

Insert over-centre spring -2- in mounting bracket from above while holding end of spring with assembly tool -T10178- in installation position.

Receptacle -arrow- for tip -A- of clutch pedal -1- must be vertical.

Insert tip -A- of clutch pedal in bearing recess of over-centre spring.

Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque.

Some cars have damping -arrow- on the clutch pedal mounting bracket.

Return it to installation position.

Install crash bar -1- and tighten bolt -2- to specified torque.

Mount cable guide -2- on steering column.

Install foot well vent -3-.

Install bracket for knee airbag.

Install trim and cover below trim on drive side.

If disconnected, connect battery.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery.

Push driver seat as far back as possible and put steering wheel in highest position.

Remove trim and cover below trim on drive side.

Vehicles with knee airbag: Remove bracket for knee airbag together with crash bar.

Continuation for all: Remove cable guide -2- from steering column.

Continuation for all: Remove footwell vent -3-.

Vehicles without knee airbag: Remove crash bar -1- (bolt -2-).

Continuation for all: If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.

To do this, remove lock washers -A- for damping.

Pull off damping.

Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.

Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-.

Swing clutch pedal forward slightly and remove over-centre spring -4- from mounting bracket.

Release tool -T10178-.

Torque wrench -V.A.G 1331-.

Install in the reverse order of removal, observing the following:

Renew self-locking nuts.

Insert over-centre spring -2- in mounting bracket from above while holding end of spring with assembly tool -T10178- in installation position.

Receptacle -arrow- for tip -A- of clutch pedal must stand vertically.

Insert tip of clutch pedal -1- in bearing recess of over-centre spring.

Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque.

Some cars have damping -arrow- on the clutch pedal mounting bracket.

Return it to installation position.

Install crash bar -1- and tighten bolt -2- to specified torque.

Mount cable guide -2- on steering column.

Install foot well vent -3-.

Install bracket for knee airbag.

Install trim and cover below trim on drive side.

If disconnected, connect battery.

Renew bolt for crash bar.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery.

Push driver seat as far back as possible and put steering wheel in highest position.

Remove trim and cover below trim on driver side.

Remove bracket for knee airbag.

Remove cable guide -2- from steering column.

Remove footwell vent -3-.

Remove crash bar -1- (bolt -2-).

If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.

To do this, remove lock washers -A- for damping.

Pull off damping.

Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.

Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-.

Swing clutch pedal forward slightly and remove over-centre spring -4- from mounting bracket.

Release clutch pedal from master cylinder with pliers -T10005-.

Remove clutch pedal.

Pliers -T10005-.

Release tool -T10178-.

Torque wrench -V.A.G 1331-.

Install in the reverse order of removal, observing the following:

Renew self-locking nuts.

Insert over-centre spring -2- in mounting bracket from above while holding end of spring with assembly tool -T10178- in installation position.

Receptacle -arrow- for tip -A- of clutch pedal must stand vertically.

Insert tip of clutch pedal -1- in bearing recess of over-centre spring.

Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque.

Some cars have damping -arrow- on the clutch pedal mounting bracket.

Return it to installation position.

Install crash bar -1- and tighten bolt -2- to specified torque.

Mount cable guide -2- on steering column.

Install foot well vent -3-.

Install bracket for knee airbag.

Install trim and cover below trim on drive side.

If disconnected, connect battery.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery.

Push driver seat as far back as possible and put steering wheel in highest position.

Remove trim and cover below trim on drive side.

Remove bracket for knee airbag.

Remove cable guide -2- from steering column.

Remove footwell vent -3-.

Remove crash bar -1- (bolt -2-).

If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.

To do this, remove lock washers -A- for damping.

Pull off damping.

Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.

Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-.

Swing clutch pedal forward slightly and remove over-centre spring -4- from mounting bracket.

Release clutch pedal from master cylinder with pliers -T10005-.

Remove clutch pedal.

Install in the reverse order of removal, observing the following:

Renew self-locking nuts.

Attach retainer -2- to master cylinder operating rod -1-.

Press retainer into notch in clutch pedal -3- until it can be heard to engage.

Insert over-centre spring -2- in mounting bracket from above while holding end of spring with assembly tool -T10178- in installation position.

Receptacle -arrow- for tip -A- of clutch pedal -1- must be vertical.

Insert tip -A- of clutch pedal in bearing recess of over-centre spring.

Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque.

Some cars have damping -arrow- on the clutch pedal mounting bracket.

Return it to installation position.

Install crash bar -1- and tighten bolt -2- to specified torque.

Mount cable guide -2- on steering column.

Install foot well vent -3-.

Install bracket for knee airbag.

Install trim and cover below trim on drive side.

If disconnected, connect battery.

Push driver seat as far back as possible and put steering wheel in highest position.

Remove trim and cover below trim on drive side.

Remove cable guide -2- from steering column.

Remove footwell vent -3-.

Now remove crash bar -A- from in front of clutch pedal by removing bolt -B-.

Remove footwell trim by removing nuts -arrows-.

Remove bolt -1- and pull universal joint -2- from steering box.

If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.

To do this, remove lock washers -A- for damping.

Pull off damping.

Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.

Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-.

Swing clutch pedal forward slightly and remove over-centre spring -4- from mounting bracket.

Release clutch pedal from master cylinder with pliers -T10005-.

Remove clutch pedal.

Install in the reverse order of removal, observing the following:

Renew self-locking nuts.

Insert over-centre spring in mounting bracket from above.

Receptacle -arrow- for tip -A- of clutch pedal must be vertical.

Insert tip of clutch pedal in bearing recess of over-centre spring.

Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque.

Some cars have damping -arrow- on the clutch pedal mounting bracket.

Return it to installation position.

Install crash bar -A-, tightening bolt -B- to specified torque.

Fit universal joint -2- to steering box and screw in new bolt -1-.

Carry out basic setting for steering angle sender -G85- with vehicle diagnosis, testing and information system -VAS 5051-.

Install trim and cover below trim on drive side.

Renew bolts for crash bar.

Remove mounting bracket.

Carefully clamp lower section of clutch pedal in vice having protective jaw pads.

Separate clutch pedal from master cylinder.

Press over-centre spring from clutch pedal -arrow 1- while swinging mounting bracket in -direction of arrow 2-.

Carefully release tension from over-centre spring.

Swing mounting bracket back to starting position and remove over-centre spring.

Clutch pedal is separated from master cylinder.

Carefully clamp lower section of clutch pedal in vice having protective jaw pads.

Insert over-centre spring in mounting bracket.

Receptacle -arrow- for tip -A- of clutch pedal must stand vertically.

Apply release tool -T10178- to middle of over-centre spring and swing up mounting bracket.

Compress over-centre spring -arrow 1-.

At the same time, move mounting bracket downwards -arrow 2- until over-centre spring can be pressed onto locating lug -A- of clutch pedal.

WARNING: If over-centre spring is improperly installed, it will jump uncontrolled out of mounting bracket.

Place a cloth over over-centre spring.

Check operation of over-centre spring.

Do this by moving mounting bracket up and down a few times.

Connect clutch pedal to master cylinder.

Install mounting bracket, Passat.

Release tool -T10178-.

Push driver seat as far back as possible and put steering wheel in highest position.

Remove trim and cover below trim on drive side.

Remove cable guide -2- from steering column.

Remove footwell vent -3-.

The crash bar -1- in front of clutch pedal -2- may be secured in different ways.

Attachment with 2 bolts: Remove crash bar -1- (2 bolts).

Attachment with 1 bolt: Remove crash bar -1- (1 bolt -2-).

If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.

To do this, remove lock washers -A- for damping.

Pull off damping.

Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.

Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-.

Swing clutch pedal forward slightly and remove over-centre spring -4- from mounting bracket.

Release clutch pedal from master cylinder with pliers -T10005-.

Remove clutch pedal.

Pliers -T10005-.

Install in the reverse order of removal, observing the following:

Renew self-locking nuts.

Insert over-centre spring -2- in mounting bracket from above while holding end of spring with assembly tool -T10178- in installation position.

Receptacle -arrow- for tip -A- of clutch pedal must stand vertically.

Insert tip of clutch pedal -1- in bearing recess of over-centre spring.

Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque.

Some cars have damping -arrow- on the clutch pedal mounting bracket.

Return it to installation position.

The crash bar -1- in front of clutch pedal -2- may be secured in different ways.

Attachment with 2 bolts: Install crash bar -1- and tighten the 2 bolts to specified torque.

Attachment with 1 bolt: Install crash bar -1- and tighten bolt -2- to specified torque.

Install trim and cover below trim on drive side.

Renew bolts for crash bar.

Hose clamps to 25 mm -3094-.

Hose clamps to 25 mm -3094-.

Torque wrench -V.A.G 1331-.

Sealing tool -T10249-.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery.

Remove complete air filter housing if it is near battery.

Remove battery and battery tray.

Clamp off supply hose to master cylinder using hose clamp -3094-.

If necessary, loosen spring-type clip -3- with assembly tool -VAS 5024- and pull supply hose off master cylinder.

In addition, for disconnecting, you can close it with the sealing tool -T10249/1-.

Release securing clip -2- using screwdriver or a pointed object and pull pipe/hose line -1- off master cylinder.

Unclip clutch position sender -G476- from master cylinder -arrow- and remove with electrical connector attached -4-.

Remove trim and cover below trim on drive side.

Vehicles with knee airbag: Remove bracket for knee airbag together with crash bar.

Remove cable guide -2- from steering column.

Remove footwell vent -3-.

Vehicles without knee airbag: Remove crash bar -1- (bolt -2-).

Continuation for all: If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.

To do this, remove lock washers -A- for damping.

Pull off damping.

Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.

Remove securing nuts -1- and -2-.

The upper securing nut -1- is accessible between the relay carrier and the steering column trim.

Remove mounting bracket -3-.

Install in the reverse order of removal, observing the following:

Renew self-locking nuts.

Some cars have damping -arrow- on the clutch pedal mounting bracket.

Install crash bar -1- and tighten bolt -2- to specified torque.

Mount cable guide -2- on steering column.

Install foot well vent -3-.

Vehicles with knee airbag: Install bracket for knee airbag together with crash bar.

Continuation for all: Install trim and cover below trim on drive side.

If disconnected, connect battery.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery.

Vehicles with turbo diesel engine and particle filter: Remove shielding -A- from particle filter.

Continuation for all: A heat shield is installed in conjunction with some engines. Appearance may be different from that illustrated.

Remove heat shield from pipe/hose line -arrows-.

Note: During the following work, ensure that no brake fluid lands on longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.

Note: Place a lint-free cloth under the master cylinder.

Clamp off supply hose to master cylinder using hose clamp -3094-.

Pull supply hose 3 off master cylinder.

In addition, for disconnecting, you can seal supply hose with sealing tool -T10249/1-.

Release securing clip -1- with a screwdriver or a pointed object and pull pipe/hose line -2- off master cylinder.

Unclip clutch position sender -G476- from master cylinder -arrow- and remove with electrical connector attached -4-.

Note: When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.

Remove trim and cover below trim on drive side.

Golf: Remove bracket for knee airbag.

Note: The installation location of the knee airbag is above the pedal cluster.

Continuation for all: Remove cable guide -2- from steering column.

Remove footwell vent -3-.

Vehicles without knee airbag: Remove crash bar -1- (bolt -2-).

To do this, remove lock washers -A- for damping.

Pull off damping.

Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.

Remove securing nuts -1- and -2-.

The upper securing nut -1- is accessible between the relay carrier and the steering column trim.

Remove mounting bracket -3-.

Hose clamps to 25 mm -3094-.

Sealing tool -T10249-.

Hook -3438-.

Torque wrench -V.A.G 1331-.

Install crash bar -1- and tighten bolt -2- to specified torque.

Mount cable guide -2- on steering column.

Install foot well vent -3-.

Install bracket for knee airbag.

Install trim and cover below trim on drive side.

Press pipe/hose line -1- with seal -2- onto connection of master cylinder -4- until securing clip -3- engages audibly.

Test line by tugging on it.

After removing hose clamp -3094- , return supply hose to its original position, if necessary.

Bleed clutch system.

Install battery tray, battery cover and battery.

If removed, install complete air filter housing.

Reconnect battery and perform work required after connecting battery.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery.

Remove complete air filter housing if it is near battery.

Remove battery, battery cover and battery tray.

Clamp off supply hose to master cylinder using hose clamp -3094-.

If necessary, loosen spring clip -3- using assembly tool -VAS 5024-.

In addition, for disconnecting, you can close it with the sealing tool -T10249/1-.

Pull off supply hose.

Pull clip -2- for pipe/hose line out of master cylinder to stop.

Pull pipe/hose line -1- out from master cylinder and seal hose.

Unclip clutch position sender -G476- from master cylinder -arrow- and remove with electrical connector attached -4-.

Note: When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.

Remove trim and cover below trim on drive side.

Remove bracket for knee airbag.

Remove cable guide -2- from steering column.

Remove footwell vent -3-.

Remove crash bar -1- (bolt -2-).

If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.

To do this, remove lock washers -A- for damping.

Pull off damping.

Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.

Remove securing nuts -1- and -2-.

The upper securing nut -1- is accessible between the relay carrier and the steering column trim.

Remove mounting bracket -3-.

Install in the reverse order of removal, observing the following:

Renew self-locking nuts.

Renew hose clips.

Allocate all components according to Electronic parts catalogue “ETKA” .

If present, install retaining clip for front parking aid warning buzzer -H22-.

Install crash bar -1- and tighten bolt -2- to specified torque.

Install lower steering column trim.

Install driver side footwell cover.

Mount cable guide -2- on steering column.

Install footwell vent -3-.

Install bracket for knee airbag.

Install trim and cover below trim on drive side.

Push pipe/hose line -1- with seal -2- onto connection of master cylinder -4- until securing clip -3- engages audibly.

Test line by tugging on it.

After removing hose clamp -3094- , return supply hose to its original position, if necessary.

Bleed clutch system.

Install battery tray, battery cover and battery.

If removed, install complete air filter housing.

Reconnect battery and perform work required after connecting battery.

Renew bolt for crash bar.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

Remove lower steering column trim.

With ignition switched off, disconnect battery.

Remove complete air filter housing if it is near battery.

Remove battery and battery tray.

Clamp off supply hose to master cylinder using hose clamp -3094-.

If necessary, loosen spring-type clip -3- with assembly tool -VAS 5024- and pull supply hose off master cylinder.

In addition, for disconnecting, you can close it with the sealing tool -T10249/1-.

Release securing clip -2- with a screwdriver or a pointed object and pull out of master cylinder to stop.

Pull pipe/hose line -1- out from master cylinder and seal hose.

Separate electrical connector -4- at clutch position sender -G476-.

Remove driver side footwell cover.

Remove crash bar -1- by removing bolt -2-.

If present, remove retaining clip -1- and swing front parking aid warning buzzer -H22- -2- in -direction of arrow-.

Pull off damping if lower securing bolt for mounting bracket is covered, -arrows-.

Remove securing nuts -1- and -2-.

The upper securing nut -1- is accessible through the opening in the lower steering column trim.

Pull mounting bracket -3- off studs on body.

Install in reverse order of removal. During this step, observe the following:

Renew self-locking nuts.

Renew hose clips.

Allocate all components according to Electronic parts catalogue “ETKA” .

If present, install retaining clip for front parking aid warning buzzer -H22-.

Install crash bar -1- and tighten bolt -2- to specified torque.

Install lower steering column trim.

Install driver side footwell cover.

Push pipe/hose line -1- with seal -2- onto connection of master cylinder -4- until securing clip -3- engages audibly.

Test pipe/hose line by tugging on it.

After removing hose clamp -3094- , return supply hose to its original shape, if necessary.

Bleed clutch system.

Install battery tray, battery cover and battery.

If removed, install complete air filter housing.

Reconnect battery and perform work required after connecting battery.

Remove mounting bracket, Golf 2009 LHD.

Remove mounting bracket, Golf 2009 right-hand drive and Golf Plus right-hand drive.

Remove mounting bracket, Golf Plus.

Remove mounting bracket, Passat.

Remove mounting bracket, Golf 2004.

Remove mounting bracket, Golf 2009 LHD.

Remove mounting bracket, Golf 2009 right-hand drive and Golf Plus right-hand drive.

Remove mounting bracket, Golf Plus left-hand drive.

Remove mounting bracket, Passat.

Install mounting bracket, Golf 2004.

Install mounting bracket, Golf 2009 LHD.

Install mounting bracket, Golf 2009 right-hand drive and Golf Plus right-hand drive.

Install mounting bracket, Golf Plus left-hand drive.

Install mounting bracket, Passat.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery.

Remove complete air filter housing if it is near battery.

Remove battery and battery tray.

RHD: In vehicles with particle filter, remove shielding -A- from particle filter.

An insulation mat is installed in conjunction with some engines. Appearance may be different from that illustrated.

Remove heat shield from pipe/hose line -arrows-.

Continuation for all: If a pipe/hose line -1- with a round component is installed directly beneath the master cylinder, the pipe/hose line must be removed.

Clamp off supply hose to master cylinder using hose clamp -3094-.

Pull supply hose 3 off master cylinder.

In addition, for disconnecting, you can seal supply hose with sealing tool -T10249/1-.

Release securing clip -2- using screwdriver or a pointed object and pull pipe/hose line -3- off master cylinder.

Unclip clutch position sender -G476- from master cylinder -arrow- and remove with electrical connector attached -4-.

Note: When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.

Remove trim and cover below trim on drive side.

Golf: Remove bracket for knee airbag.

Note: The installation location of the knee airbag is above the pedal cluster.

Continuation for all: Remove cable guide -2- from steering column.

Remove footwell vent -3-.

Vehicles without knee airbag: Remove crash bar -1- (bolt -2-).

If the pipe/hose line was removed: Push pipe/hose line -1- with seal -2- onto connection of master cylinder -4- until securing clip -3- engages audibly.

Test pipe/hose line by tugging on it.

After removing hose clamp -3094- , return supply hose to its original position, if necessary.

Bleed clutch system.

Right-hand drive: In vehicles with particle filter, install shielding -A- on particle filter.

LHD: Install battery tray and battery.

If removed, install complete air filter housing.

Reconnect battery and perform work required after connecting battery.

Hose clamps -3094-.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery.

Remove complete air filter housing if it is near battery.

Remove battery and battery tray.

RHD: In vehicles with particle filter, remove shielding -A- from particle filter.

An insulation mat is installed in conjunction with some engines. Appearance may be different from that illustrated.

Remove heat shield from pipe/hose line -arrows-.

Continuation for all: If a pipe/hose line -1- with a round component is installed directly beneath the master cylinder, the pipe/hose line must be removed.

Clamp off supply hose to master cylinder using hose clamp -3094-.

Pull supply hose 3 off master cylinder.

In addition, for disconnecting, you can seal supply hose with sealing tool -T10249/1-.

Release securing clip -1- with a screwdriver or a pointed object and pull pipe/hose line -2- off master cylinder.

Unclip clutch position sender -G476- from master cylinder -arrow- and remove with electrical connector attached -3-.

Note: When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.

Remove trim and cover below trim on drive side.

Golf: Remove bracket for knee airbag.

Note: The installation location of the knee airbag is above the pedal cluster.

Continuation for all: Remove cable guide -2- from steering column.

Remove footwell vent -3-.

Remove crash bar -1- (bolt -2-).

If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket.

To do this, remove lock washers -A- for damping.

Pull off damping.

Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.

Remove securing nuts -1- and -2-.

The upper securing nut -1- is accessible between the relay carrier and the steering column trim.

Remove mounting bracket -3-.

If the pipe/hose line was removed: Push pipe/hose line -1- with seal -2- onto connection of master cylinder -4- until securing clip -3- engages audibly.

Test line by tugging on it.

After removing hose clamp -3094- , return supply hose to its original position, if necessary.

Bleed clutch system.

Install battery tray and battery.

If removed, install complete air filter housing.

Reconnect battery and perform work required after connecting battery.

Install trim and cover below trim on drive side.

Press pipe/hose line -2- with seal into connection of master cylinder.

Attach support -B- to gearbox.

Press pipe/hose line -A- into retainer -B- on gearbox.

Install cable support bracket on gearbox and tighten bolts -arrows- to specified torque.

Install gearbox selector lever -A-.

Tighten hexagon nut -arrow 4- to specified torque.

Spread a small amount of grease on pin of gearbox selector lever -A-.

Connect gear selector cable to gearbox selector lever -arrow 1-.

Metal relay lever: Install relay lever -B- and secure with securing clip -arrow 3-.

Spread a small amount of grease on pin of relay lever -B-.

Connect gate selector cable to relay lever -arrow 2-.

Plastic relay lever: Install relay lever together with cable end-piece.

Continuation for all: Adjust selector mechanism.

Install front wall of plenum chamber.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery.

If the lifting eyes of the engine for support bracket -10 – 222 A are covered by a component, for example the air filter, it must be removed now.

Remove complete air filter housing if it is near battery.

Remove battery and battery tray.

Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

Pull gear selector cable off pin.

Metal relay lever: Remove securing clip -arrow 2- for gate selector cable from relay lever -B-.

Pull gate selector cable from pin.

Pull securing clip -arrow 3- off relay lever -B- and remove relay lever.

Plastic relay lever: Remove relay lever together with cable end-piece.

Continuation for all: Remove gearbox selector lever -A- by removing nut -arrow 4-.

Remove cable support bracket from gearbox -arrows-.

Then raise and secure gear selector cable and gate selector cable.

Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.

Then remove gearbox support -arrow A-.

Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes.

Caution: Do not operate clutch pedal any more.

Remove earth strap at upper engine/gearbox connecting bolt.

Pull connector -arrow 1- off reversing light switch -F4-.

Now remove connector -arrow 2- and wire -arrow 3- from starter.

Then remove upper securing bolt on starter.

Remove upper engine/gearbox connecting bolts.

If there are hose and cable connections in area of engine support eye for support bracket -10 – 222 A- , remove these now.

Set up support bracket -10 – 222 A- in front of bonnet support. Use: Adapter -10 – 222 A /8- , Adapter -10 – 222 A /3- and Adapter -10 – 222 A /16-.

Attach hook -10 – 222 A /10- at front right of engine.

Rear left engine support eye points towards side -arrow-:

Attach shackle -10-222 A /12- at rear left of engine -arrow-.

Attach hook -10-222 A /2- in shackle -10-222 A /12-.

Then connect hook -10-222 A /2- using adapter -10-222 A /16-.

Rear left engine support eye points upwards -arrow-:

Insert hook -10-222 A /2-.

Then connect hook -10-222 A /2- using adapter -10-222 A /16-.

Continuation for all: Take up weight of engine/gearbox assembly on spindles.

Raise vehicle.

Remove noise insulation.

Remove lower part of front left wheel housing liner.

Then remove all lines from gearbox.

Remove drive shaft heat shield, if present -arrows-.

Disconnect drive shafts from flange shafts and tie up as high as possible, being careful not to damage surface protection.

Remove pendulum support -arrows A-, -B- and -C-.

Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting.

Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10 – 222 A-.

Securing bolts -arrows- for gearbox bracket -A- must be accessible.

Remove gearbox bracket -A- -arrows-.

If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it.

Remove exhaust system strut -1- from gearbox -arrow-.

Remove starter.

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque.

Align engine and gearbox in installation position using both spindles of support bracket -10 – 222 A-.

Install new bolts -arrows- for left assembly mounting in gearbox mounting and tighten to specified torque.

WARNING: Do not remove support bracket -10 – 222 A- until the bolts securing the left and right assembly mountings have been tightened to specified torque.

Note: Install engine and gearbox mounting free of tension.

Install slave cylinder and tighten bolts -arrows B- to specified torque.

Then install gearbox support -arrow A- and tighten to specified torque.

Attach drive shafts to gearbox.

Install drive shaft heat shield, if present -arrows-.

Install pendulum support.

Assemble exhaust system and attach exhaust system bracket to subframe.

Bolt exhaust system strut -1- onto gearbox and tighten bolt -arrow- to specified torque.

Push connector -1- onto reversing light switch -F4-.

Install starter, push on connector -arrow 2- and bolt on wire -arrow 3-.

Install earth strap at upper engine/gearbox connecting bolt.

Attach support -B- to gearbox.

Press pipe/hose line -A- into retainer -B- on gearbox.

Install cable support bracket on gearbox and tighten bolts -arrows- to specified torque.

Install gearbox selector lever -A-.

Tighten hexagon nut -arrow 4- to specified torque.

Spread a small amount of grease on pin of gearbox selector lever -A-.

Connect gear selector cable to gearbox selector lever -arrow 1-.

Metal relay lever: Install relay lever -B- and secure with securing clip -arrow 3-.

Spread a small amount of grease on pin of relay lever -B-.

Connect gate selector cable to relay lever -arrow 2-.

Plastic relay lever: Install relay lever together with cable end-piece.

Continuation for all: Adjust selector mechanism.

Install battery tray, battery cover and battery.

Install engine cover and air filter housing.

Reconnect battery and perform work required after connecting battery.

Install lower part of front left wheel housing liner.

Install noise insulation.

For vehicles with front vehicle level sender -G78- , check headlight adjustment.

Support bracket -10 – 222 A-.

Adapter -10 – 222 A /8-.

Hook – 10 – 222 A /2-.

Adapter -10 – 222 A /3-.

Adapter -10 – 222 A /16-.

Gearbox support -3282-.

Rear left engine support eye points towards side shackle -10-222 A /12-.

Support bracket -10 – 222 A-.

Adapter -10-222 A /8-.

Adapter -10 – 222 A /18-.

Adjustment plate -3282/39-.

Support elements for gearbox (determine when setting adjustment plate on gearbox support).

Gearbox support -3282-.

Adapter -10-222 A /3-.

Engine and gearbox jack -V.A.G 1383A-.

Retainer -T10346-.

Engine support -3300 A-.

Torque wrench -V.A.G 1331-.

Torque wrench -V.A.G 1332-.

Gearbox lifting tackle -3336- for transporting gearbox.

Grease for clutch plate splines -G 000 100-.

Flange bolt M6 x 20.

Flange bolt M6 x 80.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery.

If the lifting eyes of the engine for support bracket -10 – 222 A are covered by a component, for example the air filter, it must be removed now.

Remove complete air filter housing if it is near battery.

Remove battery and battery tray.

Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

Pull gear selector cable off pin.

Release end-piece from gate selector cable.

Press catch -arrow 2- down to stop and remove relay lever together with cable end-piece. In the process, swing it in direction of operation.

Remove gearbox selector lever -A- by removing nut -arrow 3-.

Remove cable support bracket from gearbox -arrows-.

Then raise and secure gear selector cable and gate selector cable.

Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.

Then remove gearbox support -arrow A-.

Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes.

Caution: Do not operate clutch pedal any more.

Remove earth strap at upper engine/gearbox connecting bolt.

Pull connector -arrow 1- off reversing light switch -F4-.

Now remove connector -arrow 2- and wire -arrow 3- from starter.

Then remove upper securing bolt on starter.

Remove upper engine/gearbox connecting bolts.

Bolt bracket -T10346- to rear of the three mounting holes for battery tray.

To do this, use a collar bolt M 6 x 80 or a securing bolt for battery tray.

If there are hose and cable connections in area of engine support eye for support bracket -10 – 222 A- , remove these now.

Set up support bracket -10-222 A- in front of bonnet support. Use: Adapter -10-222 A /3- , Adapter -10-222 A /8- , Adapter -10-222 A /18-.

Position adapter -10-222 A /8- : On upper longitudinal carrier, directly before the elevation (-arrow 1-) next to bolt (-arrow 2-).

Connect bracket -T10346- to support bracket.

Attach spindles in left engine support eyes.

Take up weight of engine/gearbox assembly and support bracket on spindles.

Raise vehicle.

Remove noise insulation.

Remove lower part of front left wheel housing liner.

Then remove all lines from gearbox.

Remove pendulum support.

Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting.

Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10 – 222 A-.

Securing bolts -arrows- for gearbox bracket -A- must be accessible.

Remove gearbox bracket -A- -arrows-.

If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it.

Remove exhaust system strut -1- from gearbox -arrow-.

Remove starter.

Align engine and gearbox in installation position using both spindles of support bracket -10 – 222 A-.

Install new bolts -arrows- for left assembly mounting in gearbox mounting and tighten to specified torque.

WARNING: Do not remove support bracket -10 – 222 A- until the bolts securing the left and right assembly mountings have been tightened to specified torque.

Note: Install engine and gearbox mounting free of tension.

Then install drive shafts.

Install drive shaft heat shield, if present -arrows-.

Install pendulum support.

Assemble exhaust system and attach exhaust system bracket to subframe.

Bolt exhaust system strut -1- onto gearbox and tighten bolt -arrow- to specified torque.

Gearboxes for vehicles with start-stop system: join connector -arrow- to gearbox neutral position sender -G701-.

Install slave cylinder and tighten bolts -arrows B- to specified torque.

Then install gearbox support -arrow A- and tighten to specified torque.

Attach support -B- to gearbox.

Press pipe/hose line -A- into retainer -B- on gearbox.

Install cable support bracket on gearbox and tighten bolts -arrows- to specified torque.

Install gearbox selector lever -A-.

Tighten hexagon nut -arrow 4- to specified torque.

Spread a small amount of grease on pin of gearbox selector lever -A-.

Connect gear selector cable to gearbox selector lever -arrow 1-.

Install relay lever together with cable end-piece.

Adjust selector mechanism.

Install battery tray, battery cover and battery.

Install engine cover and air filter housing.

Reconnect battery and perform work required after connecting battery.

Install lower part of front left wheel housing liner.

Install noise insulation.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery.

Then remove engine cover with air filter.

Remove battery and battery tray.

Release end-piece from gate selector cable.

Pull clip -arrow 1- off and remove relay lever together with cable end-piece.

Remove securing clip -arrow 2- for gear selector cable from gearbox selector lever -A-.

Pull gear selector cable off pin.

Remove gearbox selector lever -A- by removing nut -arrow 3-.

Remove cable support bracket from gearbox -arrows-.

Then raise and secure gear selector cable and gate selector cable.

Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.

Then remove gearbox support -arrow A-.

Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes.

Pull connector -arrow 1- off reversing light switch -F4-.

Now remove connector -arrow 2- and wire -arrow 3- from starter.

Remove earth strap at upper engine/gearbox connecting bolt.

Then remove upper securing bolt on starter.

Remove upper engine/gearbox connecting bolts.

To prevent damage to vacuum hose from brake servo to engine, it must be removed from engine -arrow-.

If heat shield is installed, remove it from subframe -arrows-.

Screw support -T10036- or support -T10036 A- tightly onto subframe using 2 hexagon socket head bolts M6 × 20 -arrows-.

Secure engine support -3300 A- onto support -A-.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To install gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- on adjustment plate as shown.

Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.

Align adjustment plate parallel to gearbox and lock safety support on gearbox.

Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Remove lower engine/gearbox connecting bolts.

Separate exhaust system if lower bolts -arrows- cannot be removed.

Press gearbox off dowel sleeves and carefully swing towards subframe.

Turn gearbox downwards in vicinity of differential.

Carefully lift gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

Using spindles of gearbox support -3282- , tilt gearbox upwards in vicinity of differential.

Raise gearbox to engine.

Align gearbox to engine and join.

Screw in lower engine/gearbox securing bolts and tighten to specified torque.

After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.

Remove engine support -3300 A- and bracket -T10346-.

If small cover plate had been installed behind the right-hand flange shaft -A-, install it -arrows-.

Screw in upper engine/gearbox securing bolts and tighten to specified torque.

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque.

If heat shield was removed, bolt it onto subframe, -arrows-.

Screw in upper engine/gearbox securing bolts and tighten to specified torque.

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque.

Align engine and gearbox in installation position using both spindles of support bracket -10 – 222 A-.

Install new bolts -arrows- for left assembly mounting in gearbox mounting and tighten to specified torque.

WARNING: Do not remove support bracket -10 – 222 A- until the bolts securing the left and right assembly mountings have been tightened to specified torque.

Note: Install engine and gearbox mounting free of tension.

Then install drive shafts.

Install drive shaft heat shield, if present -arrows-.

Install pendulum support.

Assemble exhaust system and attach exhaust system bracket to subframe.

If front vehicle level sender -G78- -arrows- is present, install it.

Install vacuum hose -arrow-.

Install slave cylinder and tighten bolts -arrows B- to specified torque.

Then install gearbox support -arrow A- and tighten to specified torque.

Push connector -1- onto reversing light switch -F4-.

Install starter, push on connector -arrow 2- and bolt on wire -arrow 3-.

Install earth strap at upper engine/gearbox connecting bolt.

Attach support -B- to gearbox.

Press pipe/hose line -A- into retainer -B- on gearbox.

Install cable support bracket on gearbox and tighten bolts -arrows- to specified torque.

Install gearbox selector lever -A-.

Tighten hexagon nut -arrow 4- to specified torque.

Spread a small amount of grease on pin of gearbox selector lever -A-.

Connect gear selector cable to gearbox selector lever -arrow 1-.

Install relay lever -B- and secure with securing clip -arrow 3-.

Spread a small amount of grease on pin of relay lever -B-.

Connect gate selector cable to relay lever -arrow 2-.

Plastic relay lever: Install relay lever together with cable end-piece.

Continuation for all: Adjust selector mechanism.

Install battery tray, battery cover and battery.

Install complete air filter housing.

Install engine cover.

Reconnect battery and perform work required after connecting battery.

Install lower part of front left wheel housing liner.

Install noise insulation.

Remove noise insulation.

Remove complete air filter housing -1- with intake hose -2-.

Remove battery -3-, battery cover and battery tray.

Remove bolt -arrow- and valve block -4- from front wall of plenum chamber.

Remove noise insulation -5- from front wall of plenum chamber.

Remove front wall of plenum chamber.

Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

Pull gear selector cable off pin.

Metal relay lever: Remove securing clip -arrow 2- for gate selector cable from relay lever -B-.

Pull gate selector cable from pin.

Pull securing clip -arrow 3- off relay lever -B- and remove relay lever.

Plastic relay lever: Remove relay lever together with cable end-piece.

Continuation for all: Remove gearbox selector lever -A- by removing nut -arrow 4-.

Remove cable support bracket from gearbox -arrows-.

Then raise and secure gear selector cable and gate selector cable.

Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.

Then remove gearbox support -arrow A-.

Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes.

Remove earth strap at upper engine/gearbox connecting bolt.

Pull off reversing light connector -arrow 1-.

Now remove connector -arrow 2- and wire -arrow 3- from starter.

Then remove upper securing bolt on starter.

Remove upper engine/gearbox connecting bolts.

If there are hose and cable connections in area of engine support eye for support bracket -10 – 222 A- , remove these now.

Set up support bracket -10-222 A- in front of bonnet support. Use: Adapter -10-222 A /8- , Adapter -10-222 A /18-.

Position adapter -10-222 A /8- : On upper longitudinal carrier, directly before the elevation (-arrow 1-) next to bolt (-arrow 2-).

Connect bracket -T10346- to support bracket.

Attach spindles in left engine support eyes.

Take up weight of engine/gearbox assembly and support bracket on spindles.

Raise vehicle.

Remove noise insulation.

Remove lower part of front left wheel housing liner.

Then remove all lines from gearbox.

Press gearbox off dowel sleeves and carefully swing towards subframe.

Turn gearbox downwards in vicinity of differential.

Carefully lower gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- .

Note: Be careful of all lines when lowering gearbox.

Install in the reverse order of removal, observing the following:

Refer to procedure “Removing gearbox” for required special tools.

Observe the following table on the subject of “checking and topping up gear oil”.

All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap.

Always renew self-locking bolts and nuts.

Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.

If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

Ensure that intermediate plate is correctly seated on engine.

Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100-.

The clutch plate must slide easily to and fro on the input shaft.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

In the process, position bracket -T10346- at the same angle as the engine.

Secure engine support -3300 A- to bracket -T10346-.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To install gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- ( pin -3282/29- ) on adjustment plate as shown.

Place gearbox on engine and gearbox jack.

Align adjustment plate and gearbox parallel to one another.

Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel.

Using spindles of gearbox support -3282- , tilt gearbox downwards in vicinity of differential.

Carefully raise gearbox, guiding with right flange shaft -A- past flywheel and intermediate plate as shown.

Using spindles of gearbox support -3282- , tilt gearbox upwards in vicinity of differential.

Raise gearbox to engine.

Align gearbox to engine and join.

Screw in lower engine/gearbox securing bolts and tighten to specified torque.

After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.

Remove engine support -3300 A- and support.

If small cover plate had been installed behind the right-hand flange shaft -A-, install it -arrows-.

Screw in upper engine/gearbox securing bolts and tighten to specified torque.

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery.

If the lifting eyes of the engine for support bracket -10 – 222 A are covered by a component, for example the air filter, it must be removed now.

Then remove complete air filter housing.

Remove battery, battery cover and battery tray.

Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

Pull gear selector cable off pin.

Remove flange shaft securing bolt by screwing two bolts into flange and counterholding flange shaft with a lever.

Pull out flange shaft with compression spring.

Remove gearbox housing cover -arrow-.

Remove selector fork for 5th gear as follows:

Cover openings with a cloth.

Move selector fork -1- to neutral position.

Remove bolt -2- with selector fork for 5th gear.

Then remove both bolts -arrows- for pivot pins.

Pull out pivot pins.

Remove selector fork.

Spring -3- and locking collar -4- do not need to be removed.

Remove bolts -A- for synchro-hub and gear wheel for 5th gear. To do this, engage 5th gear -arrow 1- and 1st gear -arrows 2- and -3-.

After both gears are engaged, the input shaft and output shaft are locked. The synchro-hub and gear wheel cannot turn. Both bolts can now be loosened.

Note: If shafts are not to be renewed, carefully clean residual locking material out of threaded holes using a thread chaser.

Pull off synchro-hub for 5th gear together with locking collar and locking pieces.

Use puller -T10309-.

First set half sleeve -T10309/1- between 5th gear wheel -A and support for selector fork for 5th gear -B-.

The half sleeve -T10309/1- must be positioned beneath the synchro-ring.

If necessary, half sleeve must be pressed to end position.

Then turn half sleeve -T10309/1- to opposite side -direction of arrow-.

Set threaded insert -T10309/3- in half shell.

Now fit second half shell -T10309/1- and set tube -T10309/2- over assembly.

After parts are pulled off, check synchro-hub for damage.

Renew synchro-ring.

Remove 5th gear synchromeshed gear with needle bearing.

Pull off gear wheel for 5th gear.

First set up puller hooks -A-.

B – Thrust plate -40 – 105-.

Note: When pulling off gear wheel, ensure that hooks do not bend outwards. After pulling off gear wheel for 5th gear, examine for damage.

Remove selector forks -A- together with selector plates.

Unbolt reverse gear selector mechanism -B-.

Remove nuts -B- for output shaft bearing support.

Remove reverse gear -A-, input shaft -B- and output shaft -C- one after the other from clutch housing.

Remove differential.

Install differential.

Always renew sealing rings -arrows- for output shaft bearing support.

Screw M 8 x 100 mm studs -A- into reverse shaft support so that shaft is aligned after gearbox housing is fitted.

Align selector plates.

Note: The selector segments must be positioned in the grooves on the locking collars.

Apply sealant -AMV 188 200 03- evenly to sealing surface of clutch housing.

Fit gearbox housing.

Install reverse shaft support bolts -arrow- as follows:

Install bolt -a-.

Remove stud -A-.

Install bolt -c-.

Tightening sequence:

Tighten bolt -a- to 30 Nm.

Tighten bolt -b- to 25 Nm.

Tighten bolt -c- to 25 Nm.

Install pivot pin -arrow- for selector forks. Do this by aligning selector mechanism with a screwdriver so that respective pivot pin can be installed.

Apply sealant -AMV 188 200 03- evenly to sealing surface of cover plate.

Fit selector shaft cover plate.

Tighten bolts -A- for synchro-hub and 5th gear wheel to specified torque.

To do this, engage 5th gear -arrow 1- and 1st gear -arrows 2- and -3-.

After both gears are engaged, the input shaft and output shaft are locked. The synchro-hub and gear wheel cannot turn. Now both bolts can be tightened.

Install 5th gear selector fork.

Engage 5th gear. Loosen bolt -1-. Push locking collar and selector jaw in direction of arrow and then tighten bolt -1- to 25 Nm.

Check measurement: It must not be possible to slide a 0.2 mm feeler gauge between locking collar and gear wheel. If necessary, repeat adjustment.

Disengage 5th gear. Locking collar must now be in the neutral position. Synchro-ring must move freely.

Shift through all gears.

Install gearbox housing cover.

Fit release bearing guide sleeve.

Fit clutch release lever and release bearing.

Top up gear oil, Passat.

Note: After dismantling, always renew needle bearing in clutch housing and reverse shaft support.

Remove selector forks -A- together with selector plates.

Unbolt reverse gear selector mechanism -B-.

Remove nuts -B- for output shaft bearing support.

Remove reverse gear -A-, input shaft -B- and output shaft -C- one after the other from clutch housing.

Remove differential.

Install differential.

Always renew sealing rings -arrows- for output shaft bearing support.

Note: The figure shows only 3 of the 4 sealing rings.

Press outer race of tapered roller bearing without shim into gearbox housing using thrust piece -30 – 205-.

Fit differential into clutch housing.

Set gearbox housing in place and tighten 5 bolts to 25 Nm.

Attach dial gauge and set to “0” with 1 mm preload.

Move differential up and down. Read and note play indicated on dial gauge. (Example: 0.70 mm.)

Determine thickness of shim using the table, based on the bearing play (0.65 mm plus determined measured value).

Note: Allocate shims according to Electronic parts catalogue “ETKA” .

Remove input shaft and press outer race of tapered roller bearing out of gearbox housing using thrust plate -VW 447 i-.

Insert shims of determined thickness, thickest shim first.

If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure.

Press outer race of tapered roller bearing together with the shim into gearbox housing using thrust pad -VW 510-.

Press outer race of tapered roller bearing without shim into gearbox housing using thrust piece -30 – 205-.

Fit differential into clutch housing.

Set gearbox housing in place and tighten 5 bolts to 25 Nm.

Attach dial gauge and set to “0” with 1 mm preload.

Move differential up and down. Read and note play indicated on dial gauge. (Example: 0.70 mm.)

Determine thickness of shim using the table, based on the bearing play (0.65 mm plus determined measured value).

Note: Allocate shims according to Electronic parts catalogue “ETKA” .

Remove output shaft and pull out small tapered roller bearing outer race.

Insert shims of determined thickness, thickest shim first.

If the previously used 0.65 mm shim is to be reinstalled, check it for damage.

If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure.

The various thicknesses make it possible to achieve the exact shim thickness required.

Press in outer race of small tapered roller bearing together with the calculated shim (0.70 mm in example) into gearbox housing using thrust pad -VW 510-.

Press outer race of tapered roller bearing without shim into gearbox housing using thrust piece -30 – 205-.

Fit differential into clutch housing.

Set gearbox housing in place and tighten 5 bolts to 25 Nm.

Attach dial gauge and set to “0” with 1 mm preload.

Move differential up and down. Read and note play indicated on dial gauge. (Example: 0.70 mm.)

Determine thickness of shim using the table, based on the bearing play (0.65 mm plus determined measured value).

Note: Allocate shims according to Electronic parts catalogue “ETKA” .

Remove output shaft and pull out small tapered roller bearing outer race.

Insert shims of determined thickness, thickest shim first.

If the previously used 0.65 mm shim is to be reinstalled, check it for damage.

If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure.

The various thicknesses make it possible to achieve the exact shim thickness required.

Press in outer race of small tapered roller bearing together with the calculated shim (0.70 mm in example) into gearbox housing using thrust pad -VW 510-.

Remove complete air filter housing.

Remove noise insulation.

Gear oil specification for manual gearboxes is in Electronic parts catalogue “ETKA” .

To drain gear oil, a pivot pin for the selector forks in the gearbox must be removed, and the selector shaft must be locked in position by pressing the selector shaft down and turning the angled rod -A- upwards and pressing it in until it engages in the selector shaft.

Drain gear oil by removing oil drain plug -arrow 1- and then pivot pin -arrow 2-.

Install pivot pin -arrow 2- with a new O-ring.

Screw in oil drain plug -arrow 1-.

Now turn angled rod -A- back to original position so that selector shaft can move again.

Top up oil in container to 1.7 litres.

Check operation of selector mechanism.

Install complete air filter housing.

Install noise insulation.

Remove complete air filter housing.

Remove noise insulation.

Gear oil specification for manual gearboxes is in Electronic parts catalogue “ETKA” .

To drain gear oil, a pivot pin for the selector forks in the gearbox must be removed, and the selector shaft must be locked in position by pressing the selector shaft down and turning the angled rod -A- upwards and pressing it in until it engages in the selector shaft.

Drain gear oil by removing oil drain plug -arrow 1- and then pivot pin -arrow 2-.

Install pivot pin -arrow 2- with a new O-ring.

Screw in oil drain plug -arrow 1-.

Now turn angled rod -A- back to original position so that selector shaft can move again.

Top up oil in container to 1.7 litres.

Check operation of selector mechanism.

Install complete air filter housing.

Install noise insulation.

Remove complete air filter housing.

Remove noise insulation.

Gear oil specification for manual gearboxes is in Electronic parts catalogue “ETKA” .

To drain gear oil, a pivot pin for the selector forks in the gearbox must be removed, and the selector shaft must be locked in position by pressing the selector shaft down and turning the angled rod -A- upwards and pressing it in until it engages in the selector shaft.

Drain gear oil by removing oil drain plug -arrow 1- and then pivot pin -arrow 2-.

Install pivot pin -arrow 2- with a new O-ring.

Screw in oil drain plug -arrow 1-.

Now turn angled rod -A- back to original position so that selector shaft can move again.

Top up oil in container to 1.7 litres.

Check operation of selector mechanism.

Install complete air filter housing.

Install noise insulation.

Bleed clutch system.

Bleed clutch system after installing slave cylinder.

Bleed clutch system.

Torque wrench -V.A.G 1331- is required.

1 – Gearbox. 2 – Ball stud, 25 Nm (To remove and install, remove gearbox. Remove old grease from contact surface of clutch release lever. Lubricate with grease -G 000 100-).

3 – Input shaft seal (To remove and install, remove gearbox. Renewing).

4 – Guide sleeve (To remove and install, remove gearbox. With vulcanised O-ring. If O-ring is damaged, renew guide sleeve and O-ring together).

5 – Retaining spring (To remove and install, remove gearbox. Secure to clutch release lever).

6 – Socket head bolt, 20 Nm.

7 – Clutch release lever (To remove and install, remove gearbox. Remove and install together with release bearing).

8 – Release bearing (To remove and install, remove gearbox. Do not wash out bearing; wipe only. Renew noisy bearings. Removing from and inserting in clutch release lever. Lubricate contact surface of release lever with MoS2 grease).

9 – Hexagon bolt, 20 Nm.

10 – Slave cylinder (Removing and installing).

11 – Plunger.

12 – Assembly bolt (Secures clutch release lever when gearbox is installed. Remove after gearbox has been installed).

Removing and installing release lever together with release bearing: Unhook spring -arrow 1-. Pull off release lever -arrow 2- and release bearing. Install in reverse order of removal.

Removing and installing release bearing: Press together retaining hooks -arrows- on back of clutch release lever and remove release bearing -A- from clutch release lever. To install, press release bearing -A- into clutch release lever until retaining hooks -arrows- engage.

Special tools and workshop equipment required: Counterhold -3067-, Centring mandrel -3190 A-, Torque wrench -V.A.G 1331-, Grease for clutch plate splines -G 000 100-.

The make of the clutch can be determined by removing noise insulation.

Some notches -arrows- are located in lower region of sump between engine -A- and gearbox -B-. Check outer contour of flywheel through these notches.

In addition, a small cover plate -A- can be removed to enable inspection of flywheel’s outer contour.

Round outer contour -arrows- = Sachs clutch = -A-.

Outer contour with edges -arrows 1- and, in addition, a circumferential crease -arrow 2- = LuK clutch = -B-.

Remove gearbox.

Use counterhold -3067- to loosen bolts.

Loosen bolts in small steps and diagonally.

As bolts are removed, stop -2- with pin -1- must loosen.

If stop does not loosen, press pin towards dual-mass flywheel.

Remove pressure plate and clutch plate.

Install in the reverse order of removal, observing the following:

Renew pressure plate and clutch plate together only. Select clutch plate and pressure plate according to engine code and Electronic parts catalogue “ETKA” .

Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.

If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

Installation position of clutch plate: Lettering “Getriebeseite” (gearbox side) faces gearbox.

Checking ends of diaphragm spring: Wear to half the thickness of the diaphragm spring -arrows- is permitted.

Checking spring connections and riveted connections: Check spring connections between pressure plate and cover for cracks as well as rivet connections for secure seating.

Note: Renew clutch plates and pressure plates with damaged or loose rivet connections.

Note: Always renew pressure plate and clutch plate together.

Note: Select clutch plate and pressure plate according to engine code and Electronic Parts Catalogue (ETKA).

Note: If clutch has burnt out, thoroughly clean clutch housing, flywheel and parts of engine facing gearbox to reduce smell of burnt linings.

Clean input shaft splines and, on used clutch plates, clean hub splines; remove corrosion and apply only a very thin coat of clutch plate spline grease -G 000 100- to splines. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease.

Pressure plates are protected against corrosion and greased. Clean contact surface only. Otherwise, the service life of the clutch will be considerably reduced.

Pressure plate contact surface and clutch plate lining must make full contact with flywheel. Only then insert securing bolts.

Reverse counterhold tool -3067- for installation.

Push pressure plate onto dowel pins.

To centre clutch plate, use centring mandrel -3190 A-.

Tighten all bolts evenly by hand until bolt heads contact pressure plate.

Tighten bolts in small steps diagonally in order not to damage centring holes of pressure plate and centring pins of dual mass flywheel.

Torque setting.

Install gearbox.

Remove gearbox.

Use counterhold -3067- to loosen bolts.

Loosen bolts in small steps and diagonally.

Remove pressure plate and clutch plate.

Install in the reverse order of removal, observing the following:

Dual-mass flywheel: Removing and installing.

Ensure that centring pins fit tightly.

Contact surface for clutch lining must be free of grooves, oil and grease.

Clutch plate: Allocation, Removing and installing, Renew only together with SAC pressure plate, Installation position.

SAC pressure plate: Renew only together with clutch plate, Allocation, Removing and installing, Check ends of diaphragm spring, Checking spring connections and riveted connections, Checking position of adjusting mechanism with new pressure plates only.

M6 bolt, 13 Nm, M7 bolt, 20 Nm: Loosen or tighten diagonally in small steps.

Remove gearbox.

Note: Renew clutch plates and pressure plates with damaged or loose rivets.

Select clutch plate and pressure plate according to Electronic parts catalogue (ETKA) and engine code.

Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.

If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

Loosen or tighten bolts diagonally in stages.

Reverse position of counterhold -3067- when removing.

Note: Pressure plate contact surface and clutch plate lining must make full contact with flywheel. Tighten securing bolts diagonally and evenly to prevent damage to the pressure plate centring hole and the flywheel centring pins.

Install gearbox.

Note: Lubricate bearing positions and sliding surfaces. Allocate grease using Electronic parts catalogue (ETKA).

Remove securing clip from gear selector cable -A- and gate selector cable -B-.

To do this, raise tab using screwdriver -arrow 1- and press off securing clip -arrow 2-.

Remove gear selector cable -A- from gear lever retainer.

Remove gate selector cable -B- from retainer of gate selector lever.

Installing compression spring: Insert compression spring so that extension -A- lies on top of pin -arrow-. Then pull extension -B- down so that it sits below pin -arrow-.

The gear lever guide must project from the selector housing up to the stop.

Insert end -A- of compression spring into guide from above.

Pull end -B- of compression spring downwards and insert it next to guide (in direction of ball joint).

Carefully remove selector housing with gear lever guide from thrust piece -T10083-.

Move gate selector lever back to stop (opposite from mounting holes for gear and gate selector cable) -arrow 1-.

Grease ball stud.

Press ball stud into gate selector lever -arrow 2-.

Guides -A- and tabs -B- are not allowed to be damaged.

Place selector housing with gear lever guide into larger recess -arrow- in thrust piece -T10083-.

Locking pin -T10027 A- is required.

The following points are essential to ensure correct adjustment of selector mechanism:

Moving parts of operating elements and elements transferring force must be in proper condition.

Selector mechanism must move freely.

Gearbox, clutch and clutch mechanism must also be in proper condition.

Gearbox must be in neutral.

Remove air filter housing if bracket -A- and securing mechanism for gear selector cable and gate selector cable are not accessible.

Pull locking mechanisms on gate selector cable and gear selector cable end-pieces forward to stop -direction of arrow 1- and then turn to left to lock -direction of arrow 2-.

Secure selector shaft as follows:

Press selector shaft down -direction of arrow 1-.

While pressing down selector shaft, turn angled rod -A- in -direction of arrow 2- upwards and at the same time press it in until it engages in selector shaft.

Install gaiter with gear knob and noise insulation.

If noise insulation is present, remove it.

Now secure gear lever as follows:

Select neutral using gear lever.

Guide locking pin -T10027 A- through hole -A- into hole -B-.

Now turn locking mechanisms on gear selector cable and gate selector cable end-pieces clockwise to stop -direction of arrow-.

Spring presses locking mechanism into original position.

Now turn angled rod -A- back to original position -direction of arrow-.

Pull locking pin out of holes -A- and -B-.

If noise insulation was present, install it.

Install gaiter with gear knob and noise insulation.

Check that selector shaft moves freely.

If necessary, install complete air filter housing.

Functional check: With gearbox in neutral, selector lever must rest in gate for 3rd and 4th gear. Operate clutch. Select all gears several times. Pay particular attention to operation of reverse gear lock. If it continues to be difficult to engage a gear after repeated attempts, repeat adjustment procedure of selector mechanism.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery.

If the lifting eyes of the engine for support bracket -10 – 222 A are covered by a component, for example the air filter, it must be removed now.

Remove complete air filter housing if it is near battery.

Remove battery and battery tray.

Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

Pull gear selector cable off pin.

Release end-piece from gate selector cable.

Press catch -arrow 2- down to stop and remove relay lever together with cable end-piece. In the process, swing it in direction of operation.

Remove gearbox selector lever -A- by removing nut -arrow 3-.

Remove cable support bracket from gearbox -arrows-.

Then raise and secure gear selector cable and gate selector cable.

Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.

Then remove gearbox support -arrow A-.

Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes.

Caution: Do not operate clutch pedal any more.

Pull connector -arrow 1- off reversing light switch -F4-.

Now remove connector -arrow 2- and wire -arrow 3- from starter.

Remove earth strap at upper engine/gearbox connecting bolt.

Then remove upper securing bolt on starter.

Remove upper engine/gearbox connecting bolts.

Set up support bracket -10-222 A- in front of bonnet support. Use: Adapter -10-222 A /3- , Adapter -10-222 A /8- , Adapter -10-222 A /18-.

Position adapter -10-222 A /8- : On upper longitudinal carrier, directly before the elevation (-arrow 1-) next to bolt (-arrow 2-).

Connect bracket -T10346- to support bracket.

Attach spindles in left engine support eyes.

Take up weight of engine/gearbox assembly and support bracket on spindles.

Raise vehicle.

Remove noise insulation.

Remove lower part of front left wheel housing liner.

Then remove all lines from gearbox.

Gearboxes for vehicles with start-stop system: pull connector -arrow- from gearbox neutral position sender -G701-.

Remove drive shaft heat shield, if present -arrows-.

Remove drive shafts from flange shafts, raise as high as possible and secure. Do not damage the surface protection.

Separate exhaust system at double clamp and unbolt exhaust pipe bracket from subframe.

Remove pendulum support.

Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting.

Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10 – 222 A-.

Securing bolts -arrows- for gearbox bracket -A- must be accessible.

Remove gearbox bracket -A- -arrows-.

If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it.

If gearbox bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque.

Align engine and gearbox in installation position using both spindles of support bracket -10 – 222 A-.

Install new bolts -arrows- for left assembly mounting in gearbox mounting and tighten to specified torque.

WARNING: Do not remove support bracket -10 – 222 A- until the bolts securing the left and right assembly mountings have been tightened to specified torque.

Note: Install engine and gearbox mounting free of tension.

Then install drive shafts.

Install drive shaft heat shield, if present -arrows-.

Install pendulum support.

Assemble exhaust system and attach exhaust system bracket to subframe.

If front vehicle level sender -G78- -arrows- is present, install it.

Install vacuum hose -arrow-.

Install slave cylinder and tighten bolts -arrows B- to specified torque.

Then install gearbox support -arrow A- and tighten to specified torque.

Install gearbox selector lever -A-.

Tighten hexagon nut -arrow 4- to specified torque.

Spread a small amount of grease on pin of gearbox selector lever -A-.

Connect gear selector cable to gearbox selector lever -arrow 1-.

Install relay lever together with cable end-piece.

Adjust selector mechanism.

Install battery tray, battery cover and battery.

Install complete air filter housing.

Install engine cover.

Reconnect battery and perform work required after connecting battery.

Install lower part of front left wheel housing liner.

Install noise insulation.

Pull connector -arrow 1- off reversing light switch -F4-.

Now remove connector -arrow 2- and wire -arrow 3- from starter.

Remove earth strap at upper engine/gearbox connecting bolt.

Then remove upper securing bolt on starter.

Remove upper engine/gearbox connecting bolts.

If there are hose and cable connections in area of engine support eye for support bracket -10 – 222 A- , remove these now.

Set up support bracket -10-222 A- in front of bonnet support. Use: Adapter -10-222 A /3- , Adapter -10-222 A /8- , Adapter -10-222 A /18-.

Position adapter -10-222 A /8- : On upper longitudinal carrier, directly before the elevation (-arrow 1-) next to bolt (-arrow 2-).

Connect bracket -T10346- to support bracket.

Attach spindles in left engine support eyes.

Take up weight of engine/gearbox assembly and support bracket on spindles.

Raise vehicle.

Remove noise insulation.

Remove lower part of front left wheel housing liner.

Then remove all lines from gearbox.

Remove drive shaft heat shield, if present -arrows-.

Remove drive shafts from flange shafts, raise as high as possible and secure. Do not damage the surface protection.

Separate exhaust system at double clamp and remove exhaust pipe bracket from subframe.

Remove pendulum support.

Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting.

Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10 – 222 A-.

Securing bolts -arrows- for gearbox bracket -A- must be accessible.

Remove gearbox bracket -A- -arrows-.

If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it.

If exhaust system strut -1- is fitted, remove it from gearbox -arrow-.

Remove starter.

Install gearbox support -3282- in engine and gearbox jack -V.A.G 1383A-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- on adjustment plate as shown.

Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.

Align adjustment plate parallel to gearbox and lock safety support on gearbox.

Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Remove lower engine/gearbox connecting bolts.

Separate exhaust system if lower bolts -arrows- cannot be removed.

Press gearbox off dowel sleeves and carefully swing towards subframe.

Turn gearbox downwards in vicinity of differential.

Carefully lift gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- .

Note: Be careful of all lines when lowering gearbox.

If heat shield was removed, bolt it onto subframe, -arrows-.

Screw in upper engine/gearbox securing bolts and tighten to specified torque.

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque.

Align engine and gearbox in installation position using both spindles of support bracket -10 – 222 A-.

Install new bolts -arrows- for left assembly mounting in gearbox mounting and tighten to specified torque.

WARNING: Do not remove support bracket -10 – 222 A- until the bolts securing the left and right assembly mountings have been tightened to specified torque.

Note: Install engine and gearbox mounting free of tension.

Then install drive shafts.

Install drive shaft heat shield, if present -arrows-.

Install pendulum support.

Assemble exhaust system and attach exhaust system bracket to subframe.

If front vehicle level sender -G78- -arrows- is present, install it.

Install vacuum hose -arrow-.

Install slave cylinder and tighten bolts -arrows B- to specified torque.

Then install gearbox support -arrow A- and tighten to specified torque.

Push connector -1- onto reversing light switch -F4-.

Install starter, push on connector -arrow 2- and bolt on wire -arrow 3-.

Install earth strap at upper engine/gearbox connecting bolt.

Attach support -B- to gearbox.

Press pipe/hose line -A- into retainer -B- on gearbox.

Install cable support bracket on gearbox and tighten bolts -arrows- to specified torque.

Install gearbox selector lever -A-.

Tighten hexagon nut -arrow 4- to specified torque.

Spread a small amount of grease on pin of gearbox selector lever -A-.

Connect gear selector cable to gearbox selector lever -arrow 1-.

Install relay lever -B- and secure with securing clip -arrow 3-.

Spread a small amount of grease on pin of relay lever -B-.

Connect gate selector cable to relay lever -arrow 2-.

Plastic relay lever: Install relay lever together with cable end-piece.

Continuation for all: Adjust selector mechanism.

Install battery tray, battery cover and battery.

Install complete air filter housing.

Install engine cover.

Reconnect battery and perform work required after connecting battery.

Install lower part of front left wheel housing liner.

Install noise insulation.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery.

If the lifting eyes of the engine for support bracket -10 – 222 A are covered by a component, for example the air filter, it must be removed now.

Remove complete air filter housing if it is near battery.

Remove battery and battery tray.

Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

Pull gear selector cable off pin.

Release end-piece from gate selector cable.

Press catch -arrow 2- down to stop and remove relay lever together with cable end-piece. In the process, swing it in direction of operation.

Note: The relay lever was secured with a clip shortly after start of production.

Remove gearbox selector lever -A- by removing nut -arrow 3-.

Remove cable support bracket from gearbox -arrows-.

Then raise and secure gear selector cable and gate selector cable.

Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.

Then remove gearbox support -arrow A-.

Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes.

Caution: Do not operate clutch pedal any more.

Pull connector -arrow 1- off reversing light switch -F4-.

Now remove connector -arrow 2- and wire -arrow 3- from starter.

Remove earth strap at upper engine/gearbox connecting bolt.

Then remove upper securing bolt on starter.

Remove upper engine/gearbox connecting bolts.

Set up support bracket -10-222 A- in front of bonnet support. Use: Adapter -10-222 A /8- , Adapter -10-222 A /18-.

At a later point, support bracket -10-222 A- will be put onto longitudinal members with adapters -10 – 222 A /8-.

To prevent damage to edges of wings, cover bottom area of both adapters -10 – 222 A /8- with self-adhesive fabric tape -arrow-.

Connect bracket -T10346- to support bracket.

Attach spindles in left engine support eyes.

Take up weight of engine/gearbox assembly and support bracket on spindles.

Raise vehicle.

Remove noise insulation.

Remove lower part of front left wheel housing liner.

Then remove all lines from gearbox.

Press gearbox off dowel sleeves and carefully swing towards subframe.

Turn gearbox downwards in vicinity of differential.

Carefully lower gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- .

Note: Be careful of all lines when lowering gearbox.

Refer to procedure “Removing gearbox” for required special tools.

Observe the following table on the subject of “checking and topping up gear oil”.

All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap.

Always renew self-locking bolts and nuts.

Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.

If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

Ensure that intermediate plate is correctly seated on engine.

Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100-.

The clutch plate must slide easily to and fro on the input shaft.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

In the process, position bracket -T10346- at the same angle as the engine.

Secure engine support -3300 A- to bracket -T10346-.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To install gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- ( pin -3282/29- ) on adjustment plate as shown.

Place gearbox on engine and gearbox jack.

Align adjustment plate and gearbox parallel to one another.

Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel.

Using spindles of gearbox support -3282- , tilt gearbox downwards in vicinity of differential.

Carefully lift gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

Using spindles of gearbox support -3282- , tilt gearbox upwards in vicinity of differential.

Raise gearbox to engine.

Align gearbox to engine and join.

Screw in lower engine/gearbox securing bolts and tighten to specified torque.

After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.

Remove engine support -3300 A- and bracket -T10346-.

If small cover plate had been installed behind the right-hand flange shaft -A-, install it -arrows-.

Screw in upper engine/gearbox securing bolts and tighten to specified torque.

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque.

First check whether a coded radio is fitted. If so, obtain anti-theft code.

With ignition switched off, disconnect battery.

If the lifting eyes of the engine for support bracket -10 – 222 A are covered by a component, for example the air filter, it must be removed now.

Remove complete air filter housing if it is near battery.

Remove battery and battery tray.

Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

Pull gear selector cable off pin.

Release end-piece from gate selector cable.

Press catch -arrow 2- down to stop and remove relay lever together with cable end-piece. In the process, swing it in direction of operation.

Remove gearbox selector lever -A- by removing nut -arrow 3-.

Remove cable support bracket from gearbox -arrows-.

Then raise and secure gear selector cable and gate selector cable.

Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.

Then remove gearbox support -arrow A-.

Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes.

Pull connector -arrow 1- off reversing light switch -F4-.

Now remove connector -arrow 2- and wire -arrow 3- from starter.

Remove earth strap at upper engine/gearbox connecting bolt.

Install slave cylinder and tighten bolts -arrows B- to specified torque.

Then install gearbox support -arrow A- and tighten to specified torque.

Attach support -B- to gearbox.

Press pipe/hose line -A- into retainer -B- on gearbox.

Install cable support bracket on gearbox and tighten bolts -arrows- to specified torque.

Install gearbox selector lever -A-.

Tighten hexagon nut -arrow 4- to specified torque.

Spread a small amount of grease on pin of gearbox selector lever -A-.

Connect gear selector cable to gearbox selector lever -arrow 1-.

Install relay lever together with cable end-piece.

Adjust selector mechanism.

Install battery tray, battery cover and battery.

Install complete air filter housing.

Install engine cover.

Reconnect battery and perform work required after connecting battery.

Install lower part of front left wheel housing liner.

Install noise insulation.

Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting.

Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10 – 222 A-.

Securing bolts -arrows- for gearbox bracket -A- must be accessible.

Remove gearbox bracket -A- -arrows-.

If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

Secure engine support -3300 A- to bracket -T10346-.

Place a cloth between engine support -3300 A- and oil pan.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To install gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- ( pin -3282/29- ) on adjustment plate as shown.

Place gearbox on engine and gearbox jack.

Align adjustment plate and gearbox parallel to one another.

Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel.

Using spindles of gearbox support -3282- , tilt gearbox downwards in vicinity of differential.

Press gearbox off dowel sleeves and carefully swing towards subframe.

Turn gearbox downwards in vicinity of differential.

Carefully lower gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- .

Note: Be careful of all lines when lowering gearbox.

Refer to procedure “Removing gearbox” for required special tools.

Observe the following table on the subject of “checking and topping up gear oil”.

All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap.

Always renew self-locking bolts and nuts.

Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.

If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

Ensure that intermediate plate is correctly seated on engine.

Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100-.

The clutch plate must slide easily to and fro on the input shaft.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

In the process, position bracket -T10346- at the same angle as the engine.

Secure engine support -3300 A- to bracket -T10346-.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To install gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- ( pin -3282/29- ) on adjustment plate as shown.

Place gearbox on engine and gearbox jack.

Align adjustment plate and gearbox parallel to one another.

Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel.

Using spindles of gearbox support -3282- , tilt gearbox downwards in vicinity of differential.

Carefully lift gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

Using spindles of gearbox support -3282- , tilt gearbox upwards in vicinity of differential.

Raise gearbox to engine.

Align gearbox to engine and join.

Screw in lower engine/gearbox securing bolts and tighten to specified torque.

After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.

Remove engine support -3300 A- and bracket -T10346-.

If small cover plate had been installed behind the right-hand flange shaft -A-, install it -arrows-.

Screw in upper engine/gearbox securing bolts and tighten to specified torque.

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque.

Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting.

Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10 – 222 A-.

Securing bolts -arrows- for gearbox bracket -A- must be accessible.

Remove gearbox bracket -A- -arrows-.

If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it.

If exhaust system strut -1- is fitted, remove it from gearbox -arrow-.

Remove starter.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

Secure engine support -3300 A- to bracket -T10346-.

Place a cloth between engine support -3300 A- and oil pan.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To remove gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383A-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- on adjustment plate as shown.

Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.

Align adjustment plate parallel to gearbox and lock safety support on gearbox.

Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Remove lower engine/gearbox connecting bolts.

Separate exhaust system if lower bolts -arrows- cannot be removed.

Press gearbox off dowel sleeves and carefully swing towards subframe.

Turn gearbox downwards in vicinity of differential.

Carefully lift gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- .

Note: Be careful of all lines when lowering gearbox.

Refer to procedure “Removing gearbox” for required special tools.

Observe the following table on the subject of “checking and topping up gear oil”.

All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap.

Always renew self-locking bolts and nuts.

Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.

If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

Ensure that intermediate plate is correctly seated on engine.

Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100-.

The clutch plate must slide easily to and fro on the input shaft.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

In the process, position bracket -T10346- at the same angle as the engine.

Secure engine support -3300 A- to bracket -T10346-.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To install gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- ( pin -3282/29- ) on adjustment plate as shown.

Place gearbox on engine and gearbox jack.

Align adjustment plate and gearbox parallel to one another.

Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel.

Using spindles of gearbox support -3282- , tilt gearbox downwards in vicinity of differential.

Carefully lift gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

Using spindles of gearbox support -3282- , tilt gearbox upwards in vicinity of differential.

Raise gearbox to engine.

Align gearbox to engine and join.

Screw in lower engine/gearbox securing bolts and tighten to specified torque.

After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.

Remove engine support -3300 A- and bracket -T10346-.

If small cover plate had been installed behind the right-hand flange shaft -A-, install it -arrows-.

Screw in upper engine/gearbox securing bolts and tighten to specified torque.

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque.

Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting.

Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10 – 222 A-.

Securing bolts -arrows- for gearbox bracket -A- must be accessible.

Remove gearbox bracket -A- -arrows-.

If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it.

If exhaust system strut -1- is fitted, remove it from gearbox -arrow-.

Remove starter.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

Secure engine support -3300 A- to bracket -T10346-.

Place a cloth between engine support -3300 A- and oil pan.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To remove gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383A-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- on adjustment plate as shown.

Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.

Align adjustment plate parallel to gearbox and lock safety support on gearbox.

Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Remove lower engine/gearbox connecting bolts.

Separate exhaust system if lower bolts -arrows- cannot be removed.

Press gearbox off dowel sleeves and carefully swing towards subframe.

Turn gearbox downwards in vicinity of differential.

Carefully lower gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- .

Note: Be careful of all lines when lowering gearbox.

Refer to procedure “Removing gearbox” for required special tools.

Observe the following table on the subject of “checking and topping up gear oil”.

All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap.

Always renew self-locking bolts and nuts.

Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.

If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

Ensure that intermediate plate is correctly seated on engine.

Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100-.

The clutch plate must slide easily to and fro on the input shaft.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

In the process, position bracket -T10346- at the same angle as the engine.

Secure engine support -3300 A- to bracket -T10346-.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To install gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- ( pin -3282/29- ) on adjustment plate as shown.

Place gearbox on engine and gearbox jack.

Align adjustment plate and gearbox parallel to one another.

Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel.

Using spindles of gearbox support -3282- , tilt gearbox downwards in vicinity of differential.

Carefully lift gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

Using spindles of gearbox support -3282- , tilt gearbox upwards in vicinity of differential.

Raise gearbox to engine.

Align gearbox to engine and join.

Screw in lower engine/gearbox securing bolts and tighten to specified torque.

After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.

Remove engine support -3300 A- and bracket -T10346-.

If small cover plate had been installed behind the right-hand flange shaft -A-, install it -arrows-.

Screw in upper engine/gearbox securing bolts and tighten to specified torque.

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque.

Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting.

Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10 – 222 A-.

Securing bolts -arrows- for gearbox bracket -A- must be accessible.

Remove gearbox bracket -A- -arrows-.

If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it.

If exhaust system strut -1- is fitted, remove it from gearbox -arrow-.

Remove starter.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

Secure engine support -3300 A- to bracket -T10346-.

Place a cloth between engine support -3300 A- and oil pan.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To remove gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383A-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- on adjustment plate as shown.

Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.

Align adjustment plate parallel to gearbox and lock safety support on gearbox.

Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Remove lower engine/gearbox connecting bolts.

Separate exhaust system if lower bolts -arrows- cannot be removed.

Press gearbox off dowel sleeves and carefully swing towards subframe.

Turn gearbox downwards in vicinity of differential.

Carefully lift gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- .

Note: Be careful of all lines when lowering gearbox.

Refer to procedure “Removing gearbox” for required special tools.

Observe the following table on the subject of “checking and topping up gear oil”.

All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap.

Always renew self-locking bolts and nuts.

Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.

If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

Ensure that intermediate plate is correctly seated on engine.

Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100-.

The clutch plate must slide easily to and fro on the input shaft.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

In the process, position bracket -T10346- at the same angle as the engine.

Secure engine support -3300 A- to bracket -T10346-.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To install gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- ( pin -3282/29- ) on adjustment plate as shown.

Place gearbox on engine and gearbox jack.

Align adjustment plate and gearbox parallel to one another.

Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel.

Using spindles of gearbox support -3282- , tilt gearbox downwards in vicinity of differential.

Carefully lift gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

Using spindles of gearbox support -3282- , tilt gearbox upwards in vicinity of differential.

Raise gearbox to engine.

Align gearbox to engine and join.

Screw in lower engine/gearbox securing bolts and tighten to specified torque.

After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.

Remove engine support -3300 A- and bracket -T10346-.

If small cover plate had been installed behind the right-hand flange shaft -A-, install it -arrows-.

Screw in upper engine/gearbox securing bolts and tighten to specified torque.

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque.

Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting.

Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10 – 222 A-.

Securing bolts -arrows- for gearbox bracket -A- must be accessible.

Remove gearbox bracket -A- -arrows-.

If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it.

If exhaust system strut -1- is fitted, remove it from gearbox -arrow-.

Remove starter.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

Secure engine support -3300 A- to bracket -T10346-.

Place a cloth between engine support -3300 A- and oil pan.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To remove gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383A-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- on adjustment plate as shown.

Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.

Align adjustment plate parallel to gearbox and lock safety support on gearbox.

Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Remove lower engine/gearbox connecting bolts.

Separate exhaust system if lower bolts -arrows- cannot be removed.

Press gearbox off dowel sleeves and carefully swing towards subframe.

Turn gearbox downwards in vicinity of differential.

Carefully lift gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- .

Note: Be careful of all lines when lowering gearbox.

Refer to procedure “Removing gearbox” for required special tools.

Observe the following table on the subject of “checking and topping up gear oil”.

All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap.

Always renew self-locking bolts and nuts.

Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.

If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

Ensure that intermediate plate is correctly seated on engine.

Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100-.

The clutch plate must slide easily to and fro on the input shaft.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

In the process, position bracket -T10346- at the same angle as the engine.

Secure engine support -3300 A- to bracket -T10346-.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To install gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- ( pin -3282/29- ) on adjustment plate as shown.

Place gearbox on engine and gearbox jack.

Align adjustment plate and gearbox parallel to one another.

Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel.

Using spindles of gearbox support -3282- , tilt gearbox downwards in vicinity of differential.

Carefully lift gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

Using spindles of gearbox support -3282- , tilt gearbox upwards in vicinity of differential.

Raise gearbox to engine.

Align gearbox to engine and join.

Screw in lower engine/gearbox securing bolts and tighten to specified torque.

After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.

Remove engine support -3300 A- and bracket -T10346-.

If small cover plate had been installed behind the right-hand flange shaft -A-, install it -arrows-.

Screw in upper engine/gearbox securing bolts and tighten to specified torque.

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque.

Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting.

Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10 – 222 A-.

Securing bolts -arrows- for gearbox bracket -A- must be accessible.

Remove gearbox bracket -A- -arrows-.

If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it.

If exhaust system strut -1- is fitted, remove it from gearbox -arrow-.

Remove starter.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

Secure engine support -3300 A- to bracket -T10346-.

Place a cloth between engine support -3300 A- and oil pan.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To remove gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383A-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- on adjustment plate as shown.

Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.

Align adjustment plate parallel to gearbox and lock safety support on gearbox.

Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Remove lower engine/gearbox connecting bolts.

Separate exhaust system if lower bolts -arrows- cannot be removed.

Press gearbox off dowel sleeves and carefully swing towards subframe.

Turn gearbox downwards in vicinity of differential.

Carefully lower gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- .

Note: Be careful of all lines when lowering gearbox.

Refer to procedure “Removing gearbox” for required special tools.

Observe the following table on the subject of “checking and topping up gear oil”.

All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap.

Always renew self-locking bolts and nuts.

Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.

If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

Ensure that intermediate plate is correctly seated on engine.

Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100-.

The clutch plate must slide easily to and fro on the input shaft.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

In the process, position bracket -T10346- at the same angle as the engine.

Secure engine support -3300 A- to bracket -T10346-.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To install gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- ( pin -3282/29- ) on adjustment plate as shown.

Place gearbox on engine and gearbox jack.

Align adjustment plate and gearbox parallel to one another.

Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel.

Using spindles of gearbox support -3282- , tilt gearbox downwards in vicinity of differential.

Carefully lift gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

Using spindles of gearbox support -3282- , tilt gearbox upwards in vicinity of differential.

Raise gearbox to engine.

Align gearbox to engine and join.

Screw in lower engine/gearbox securing bolts and tighten to specified torque.

After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.

Remove engine support -3300 A- and bracket -T10346-.

If small cover plate had been installed behind the right-hand flange shaft -A-, install it -arrows-.

Screw in upper engine/gearbox securing bolts and tighten to specified torque.

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque.

Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting.

Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10 – 222 A-.

Securing bolts -arrows- for gearbox bracket -A- must be accessible.

Remove gearbox bracket -A- -arrows-.

If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it.

If exhaust system strut -1- is fitted, remove it from gearbox -arrow-.

Remove starter.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

Secure engine support -3300 A- to bracket -T10346-.

Place a cloth between engine support -3300 A- and oil pan.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To remove gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383A-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- on adjustment plate as shown.

Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.

Align adjustment plate parallel to gearbox and lock safety support on gearbox.

Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Remove lower engine/gearbox connecting bolts.

Separate exhaust system if lower bolts -arrows- cannot be removed.

Press gearbox off dowel sleeves and carefully swing towards subframe.

Turn gearbox downwards in vicinity of differential.

Carefully lower gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- .

Note: Be careful of all lines when lowering gearbox.

Refer to procedure “Removing gearbox” for required special tools.

Observe the following table on the subject of “checking and topping up gear oil”.

All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap.

Always renew self-locking bolts and nuts.

Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.

If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

Ensure that intermediate plate is correctly seated on engine.

Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100-.

The clutch plate must slide easily to and fro on the input shaft.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

In the process, position bracket -T10346- at the same angle as the engine.

Secure engine support -3300 A- to bracket -T10346-.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To install gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- ( pin -3282/29- ) on adjustment plate as shown.

Place gearbox on engine and gearbox jack.

Align adjustment plate and gearbox parallel to one another.

Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel.

Using spindles of gearbox support -3282- , tilt gearbox downwards in vicinity of differential.

Carefully lift gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

Using spindles of gearbox support -3282- , tilt gearbox upwards in vicinity of differential.

Raise gearbox to engine.

Align gearbox to engine and join.

Screw in lower engine/gearbox securing bolts and tighten to specified torque.

After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.

Remove engine support -3300 A- and support.

If small cover plate had been installed behind the right-hand flange shaft -A-, install it -arrows-.

Screw in upper engine/gearbox securing bolts and tighten to specified torque.

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque.

Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting.

Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10 – 222 A-.

Securing bolts -arrows- for gearbox bracket -A- must be accessible.

Remove gearbox bracket -A- -arrows-.

If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it.

If exhaust system strut -1- is fitted, remove it from gearbox -arrow-.

Remove starter.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

Secure engine support -3300 A- to bracket -T10346-.

Place a cloth between engine support -3300 A- and oil pan.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To remove gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383A-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- on adjustment plate as shown.

Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.

Align adjustment plate parallel to gearbox and lock safety support on gearbox.

Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Remove lower engine/gearbox connecting bolts.

Separate exhaust system if lower bolts -arrows- cannot be removed.

Press gearbox off dowel sleeves and carefully swing towards subframe.

Turn gearbox downwards in vicinity of differential.

Carefully lower gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- .

Note: Be careful of all lines when lowering gearbox.

Refer to procedure “Removing gearbox” for required special tools.

Observe the following table on the subject of “checking and topping up gear oil”.

All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap.

Always renew self-locking bolts and nuts.

Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.

If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

Ensure that intermediate plate is correctly seated on engine.

Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100-.

The clutch plate must slide easily to and fro on the input shaft.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

In the process, position bracket -T10346- at the same angle as the engine.

Secure engine support -3300 A- to bracket -T10346-.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To install gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- ( pin -3282/29- ) on adjustment plate as shown.

Place gearbox on engine and gearbox jack.

Align adjustment plate and gearbox parallel to one another.

Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel.

Using spindles of gearbox support -3282- , tilt gearbox downwards in vicinity of differential.

Carefully lift gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

Using spindles of gearbox support -3282- , tilt gearbox upwards in vicinity of differential.

Raise gearbox to engine.

Align gearbox to engine and join.

Screw in lower engine/gearbox securing bolts and tighten to specified torque.

After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.

Remove engine support -3300 A- and support.

If small cover plate had been installed behind the right-hand flange shaft -A-, install it -arrows-.

Screw in upper engine/gearbox securing bolts and tighten to specified torque.

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque.

Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting.

Tilt engine/gearbox assembly by lowering it via spindles of support bracket -10 – 222 A-.

Securing bolts -arrows- for gearbox bracket -A- must be accessible.

Remove gearbox bracket -A- -arrows-.

If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it.

If exhaust system strut -1- is fitted, remove it from gearbox -arrow-.

Remove starter.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

Secure engine support -3300 A- to bracket -T10346-.

Place a cloth between engine support -3300 A- and oil pan.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To remove gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Insert gearbox support -3282- in engine and gearbox jack -V.A.G 1383A-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- on adjustment plate as shown.

Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.

Align adjustment plate parallel to gearbox and lock safety support on gearbox.

Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Remove lower engine/gearbox connecting bolts.

Separate exhaust system if lower bolts -arrows- cannot be removed.

Press gearbox off dowel sleeves and carefully swing towards subframe.

Turn gearbox downwards in vicinity of differential.

Carefully lift gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- .

Note: Be careful of all lines when lowering gearbox.

Align adjustment plate parallel to gearbox and lock safety support on gearbox.

Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Remove lower engine/gearbox connecting bolts.

Separate exhaust system if lower bolts -arrows- cannot be removed.

Press gearbox off dowel sleeves and carefully lower.

When lowering gearbox, change position of gearbox using spindles of gearbox support -3282- .

Note: Be careful of all lines when lowering gearbox.

All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap.

Always renew self-locking bolts and nuts.

Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.

If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

Ensure that intermediate plate is correctly seated on engine.

Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100-.

The clutch plate must slide easily to and fro on the input shaft.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe.

In the process, position bracket -T10346- at the same angle as the engine.

Secure engine support -3300 A- to bracket -T10346-.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To install gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39-.

Align arms of gearbox support according to holes in adjustment plate.

Screw in support elements -A – and -C- ( pin -3282/29- ) on adjustment plate as shown.

Place gearbox on engine and gearbox jack.

Align adjustment plate and gearbox parallel to one another.

Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Position engine and gearbox jack under vehicle. -Arrow B- on adjustment plate points in direction of vehicle travel.

Using spindles of gearbox support -3282- , tilt gearbox downwards in vicinity of differential.

Carefully lift gearbox, guiding right-hand flange shaft -A- past dowel sleeve in cylinder block -arrow- as shown.

Guide left flange shaft -B- past subframe bracket -arrow- as shown.

Using spindles of gearbox support -3282- , tilt gearbox upwards in vicinity of differential.

Raise gearbox to engine.

Align gearbox to engine and join.

Screw in lower engine/gearbox securing bolts and tighten to specified torque.

After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.

Remove engine support -3300 A- and support.

If small cover plate had been installed behind the right-hand flange shaft -A-, install it -arrows-.

Screw in upper engine/gearbox securing bolts and tighten to specified torque.

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque.