Removal

CAUTION: On vehicles equipped with an anti-theft radio, make sure you know the correct radio activation code before disconnecting the battery.

Removing Screws At Radiator:

1. Disconnect the negative battery cable and insulate.
2. Detach the clutch cable.
3. Tilt the radiator forward (in direction of arrow), removing screws on both sides.
4. Disconnect all the electrical wiring from the gearbox and starter assemblies.
5. If applicable, loosen electric wire holders on coolant hoses.

Shift Linkage Removal:

6. Remove the gear shift linkage from the gearbox as follows:

a. Disconnect swivel head (arrow 1).
b. Take off front gear selector rod from gearbox shift lever (arrow 2).
c. Disconnect console with gate selector rod (arrow 3).
d. Tie up selector rod and gate selector rod.

7. Dismantle clutch controls as follows:

a. Disconnect slave cylinder from gearbox, place aside and secure with wire to avoid damage.

NOTE: Do not open the system and do not depress the clutch pedal, otherwise the clutch must be bled.

b. Remove the holder for the input shaft/speedometer from the gearbox.

Removing Coolant Pipe:

c. Remove pipe for coolant - from expansion tank to water pump - from starter (arrows).
d. Remove the wire harness from the pipe.
e. Remove upper engine/gearbox mounting bolts.

WARNING: Apply support 3250 before lifting the vehicle, otherwise the suspension of the vehicle would have to be bottomed or the vehicle loaded down again.

8. Remove left drive shaft as follows:

a. Loosen bolt for drive shaft/wheel hub with the vehicle on its wheels.
b. Remove wheel bearing housing/lower drive joint bolt, while supporting the drive joint to prevent it from falling down.
c. Remove bolt for shock absorber and connecting rod/stabilizer.
d. Remove lower engine cover.
e. Remove drive shaft from gearbox.
f. Push shock absorber together completely.
g. Remove drive shaft.

9. Remove right drive shaft from gearbox and tie up.
10. Remove bolt for shock absorber and connecting rod/stabilizer on right hand side.
11. Disconnect earthing strap from gearbox and console.
12. Remove starter.
13. Remove alternator.
14. Remove gearbox carrier from bearing housing and engine.
15. Vehicles equipped with A/C need to dismantle the A/C compressor without opening the system.

Mounting Bolts:

16. Remove mounting bolts for bonded rubber bushing (arrows).
17. Remove drive shaft for speedometer from bearing housing of right flange shaft.

Special Tool:

18. Install catching fixture 3184 as follows in order to catch the engine/gearbox assembly.
19. Install engine fixture 3227 on engine block.

Gearbox Special Tool:

20. Attach auxiliary carrier 3184/1 for catching fixture 3184 in end member (arrows) if necessary after first removing wire harnesses and pipes.
21. Attach front end of catching fixture 3184 in auxiliary carrier 3184/1, and rear end in gearbox carrier "A" Guide the pin of engine holder into bore of movable sled "B".

NOTE: Sled "B" will bear on right-hand pipe (arrow) when the catching fixture is installed correctly.

22. Tighten lifting off locks after installation of the catching fixture.
23. Preload catching fixture with spindle "C".

Gearbox Bearing Console:

24. Unscrew gearbox bearing console "A" from rubber/metal mount on body (arrow 1) first and then from gearbox (arrows 2).

NOTE: Lower gearbox to remove bearing console from gearbox.

25. Push up stabilizer at both connecting rods as far as the stop in order to have clearance for the exhaust pipe.

CAUTION: Cover the stabilizer and, if fitted, the steering damper in the area of the exhaust assembly to avoid damaging the protective paint finish.

26. Disconnect the front exhaust pipe from the primary silencer.
27. Remove engine/gearbox securing screws above bearing housing of output shaft/flange shaft on right hand side.
28. Place gearbox lifter V.A.G. 1383 underneath gearbox and remove remaining engine/gearbox securing screws.
29. Secure gearbox. Press it off of engine and lower it carefully.

NOTE: If a vehicle with mounting catching fixture 3184 has to be moved, pay attention to the following to avoid contact:

^ Screw in spindle for lowering or lifting engine/gearbox as far as stop.
^ Proceed carefully in area of vehicle lift.