Removing and Installing
5 Speed Manual 02J
Removing and Installing
Special tools
- VW 457/1 Support rails.
- 10-222 A Support
- 10-222 A/8 Adapter
- 3282 Transmission support
- 3282/8 Adjustment plate
- 3300 A Engine support
- 3336 Transmission lifting beam
- VAG 1331 Torque wrench
- VAG 1332 Torque wrench
- VAG 1383 A Engine/transmission jack
- VAS 5024 Mounting pliers
VW 457/1 support rails, modifying.
To secure support rail VW 457/1 to the subframe a new hole is required.
- Drill an 8.5 mm (0.335 inch) diameter hole (arrow) in VA/ 457/1 support rail.
Guide 10-222 A/21 of support 10-222 A, Modifying
The engine support bridge 10-222 A is used to support the engine/transmission assembly.
A new hole is required to mount the adapter 10-222 A/8 to the guide 10-222 A/21.
- Drill a 12.5 mm (0.50 inch) diameter hole (arrow) in the guide 10-222 A/21.
Removing
- Remove engine cover.
- Obtain anti-theft coding for radio.
- Switch ignition off and disconnect battery Ground strap.
- Remove power steering reservoir for battery bracket but do not loosen hoses.
- Tie reservoir up to upper radiator support.
- Disconnect battery cable and remove battery.
- Remove battery carrier.
- Remove intake hose -1- and connector -2- from air mass meter.
- Remove bolts -3- and -4-.
- Remove air cleaner complete.
Vehicles Up To 05.99
- Disconnect connector from vehicle speed sensor (arrow
- Disconnect back-up light connector (arrow -2-).
- Remove balance weight -A- and gear selector cable -B- from gear selector lever.
- Take off gear selector cable with washer and square nut.
- Lift tab in direction of arrow and remove gate selector cable from actuating arm/relay lever -C-.
- Remove cable support bracket from transmission (arrows), if necessary unclip hose at cable support bracket first.
Vehicles From 06.99
- Remove cable support bracket from transmission (arrows), if necessary unclip hose -A- at cable support bracket first.
- Pull off gate selector cable -A- with relay lever, remove circlip (arrow) to do this:
- Remove gear selector cable -B- with transmission selector lever, remove nut (arrow) to do this.
- Tie selector cable with transmission selector lever and gate selector cable with relay lever up.
- Pull connector off road speed sensor (arrow 1).
- Pull off reverse light connector (arrow 2).
Continued For All Vehicles
- Remove slave cylinder and secure to side with wire. Do not disconnect lines.
CAUTION!
Do not depress clutch pedal with slave cylinder removed.
- Remove cable retainer (arrow -1-) on starter.
- Remove upper securing bolt (arrow -2-) on starter.
- Remove Ground strap at engine/transmission upper securing bolt.
- Remove upper engine/transmission securing bolts,
- If necessary remove hoses and wiring connections in area of engine mounting eye for support 10-222 A.
- Install support 10-222 with legs 10-222 A/1 and support engine/ transmission in position.
CAUTION!
Do not place adapters 10-222 A/8 on the fender mounting screws.
- Take weight of engine/transmission assembly on tool spindles.
- Remove sound insulation tray.
- Remove left sound insulator (arrows).
- Remove power steering line from starter and transmission mounts.
- Remove starter.
- Remove right inner constant velocity joint protective cover from engine if installed.
- Turn wheels fully left onto lock.
- Disconnect axle shafts from flanged shafts and tie up as high as possible, when doing this do not damage surface protection.
Note:
When tying up axle shafts use care not to damage the surface protection (coating, paint, etc.) of the bodywork.
- Remove flywheel small cover plate -A- behind right flanged shaft (arrows), if installed.
- It installed, remove lower flywheel cover plate.
- Separate exhaust system at down pipe.
- Remove bolts for pendulum support (arrows -A- and -B-).
- Then remove transmission support (arrows -A-) from transmission.
- Remove bolts (arrows -B-) from left assembly mounting.
- Incline engine/transmission assembly by lowering it via left spindle of support bar 10-222 A.
- Remove bolts (arrows) for transmission mount
- Remove additional fan, if installed on right side of vehicle.
- Bolt support rail VW 457/1 to both pendulum support securing holes -A- on subframe.
- Spacers totaling a thickness of 6 mm must be inserted between the subframe and the support rail VIN 457/1.
- -A- = Qty. 2 bolts M8 x 25
Note:
- Mounting rail T10036 can be used instead of mounting rail VW 457/1.
- Install support 3300 A and secure (arrows).
Vehicles With A 1.8L Engine
- Remove a lower engine/transmission securing bolt so that support 3300 A can be installed.
Note:
- The support 3300 A must be installed directly next to the transmission on the engine.
Continued For All Vehicles
- Press engine/transmission assembly forward carefully,
Note:
Do not damage power steering line when moving engine/transmission assembly.
- Assemble transmission jack with support 3282, adjustment plate 3:282/8 (same as for 02A transmission) and support elements as follows:
- Place adjustment plate 3282/8 on transmission support 3282. (Adjustment plate only fits in one position).
- Align arms of support according to holes in adjustment plate.
- Bolt on support elements -A-, as illustrated on adjustment plate.
- Place transmission jack under vehicle, arrow symbol -B- on adjustment plate points to front of vehicle.
- Align adjustment plate parallel to transmission and lock safety supports on transmission,
- Remove lower engine/transmission securing bolts.
- Press transmission off dowels and carefully swing towards subframe.
- Lower transmission carefully while guiding right flange shaft -A- in area of flywheel as illustrated. Guide left flange shaft -B- in area of subframe.
Note:
- When lowering the transmission change its position using the transmission support 3282 spindles.
- Do not damage the power steering line when lowering the transmission.
Transporting the transmission
- Bolt transmission lifting beam 3336 to clutch housing.
- Set support arm on sliding piece with locking pin (arrow).
- No. of holes visible = 5
- Remove transmission with hoist and transmission lifting beam 3336.
- Place transmission onto transport or other container.
Installing
Note:
- Before installing the transmission press the clutch release lever toward the transmission housing and secure with assembly pin, a5semblybolt or M8 x 35 bolt. Remove the pin or bolt after the transmission has been installed. The hole will then be sealed by the 3rd cable support bracket securing bolt or plugged.
- When replacing the transmission, the sensors for the speedometer (Fig.), gear selector and relay lever must be transferred to the new assembly.
- Clean input shaft splines and lubricate lightly with grease, Part NO. G 000 100.
- Clutch plate must be able to slide lightly back and forth on input shaft.
- Check whether dowel sleeves for aligning engine/transmission are installed in cylinder block-, install if necessary.
- Check that intermediate plate is correctly positioned on engine.
- Bolt support rail VW 457/1 to both pendulum support securing holes on subframe.
- Insert spacers totaling thickness of 6 mm between subframe and Support rail VW 457/1.
- -A- = Qty. 2 bolts M8 x 25
- Install support 3300 A and secure (arrows).
Vehicles With 1.8 L Engine
- The support 3300 A must sit on the threaded boss on the engine.
Continued for all vehicles
- Press engine forward carefully.
Note:
Do not damage power steering line.
- Assemble transmission jack with transmission support 3282, adjustment plate 3282/8 for "02A" transmission and support elements as follows
- Place adjustment plate 3282/8 or transmission support 3282. (Adjustment plate only fits in one position).
- Align arms of transmission support according to holes in adjustment plate.
- Bolt on support elements -A-, as illustrated on adjustment plate.
- Place transmission on transmission jack.
- Align adjustment plate and transmission parallel with one another and lock safety supports on transmission.
- Place transmission jack under vehicle, arrow symbol -B- on adjustment plate points to front of vehicle.
- Align transmission to engine.
Note:
Do not damage power steering line.
- Install lower engine/transmission securing bolts.
- Remove support 3300 A (arrows).
- Remove bolts -A- and remove support rail VW 457/1.
- Install upper engine/transmission securing bolts.
- Install transmission mount -A- with new bolts (arrows).
- Align engine/transmission in installation position.
- Install new bolts (arrows -B-) for left assembly mounting.
- Install transmission support (arrows -A-) to transmission.
WARNING!
Do not remove support bar 10-222A until the bolts securing the left transmission mount have been tightened to the correct torque setting.
- Install lower engine/transmission securing bolt (arrow A).
- Install pendulum support (arrows) and use new bolts to secure.
- Reconnect exhaust system.
- Install retainer for power steering line on starter and on transmission.
- If removed, install small cover plate (arrows) behind right axle flange -A- .
- If removed, install large cover plate for clutch.
- Install axle shafts to transmission.
- If removed, install protective cap for right inner constant velocity joint to engine.
- Install starter.
- Install clutch slave cylinder.
Vehicles Up To 05.99
- Install cable support bracket on transmission (arrows). If necessary push hose onto cable support bracket.
- Install gear selector cable -B- and balance weight -A- on gear selector lever.
- Lift tab in direction of arrow to install gate selector cable on follower/relay lever -C-.
Vehicles As Of 06.99
- Install cable support bracket to transmission -arrows-, press hose -A- on to cable support bracket.
- Install gear selector cable -B- with transmission selector lever (arrow).
- Install gate selector cable -A- with relay lever and secure (arrow).
Continued For All Vehicles
- Connector back-up light connector (arrow -2-).
- Connect all other electrical connections and Ground wires to transmission and to engine/transmission securing bolts.
- Connect connector to vehicle speed sensor (arrow
- Assemble air intake duct
- Install battery carrier.
- Install battery.
- Connect Ground strap to battery.
Note:
Return code to radio on vehicles with coded radio.
- Connect reservoir for power steering on battery bracket.
- Check transmission oil.
- Adjust gear shift linkage.
- Install engine cover.
- Install sound insulation tray.
Tightening Torques
Transmission To Engine
1) In addition, starter to transmission
2) Small cover plate for flywheel
Items A + B - Dowel sleeves
Transmission Console -A- To Transmission
- Replace bolts
- Bolts -arrows-: 50 Nm + 90°
Transmission To Body
- Replace bolts -B-.
- Bolts -A-: 25 Nm
- Bolts -B-: 6O Nm + 90°
Rear Transmission Mounting
- Replace bolts
- Bolts -A-: 20 Nm + 90°
- Bolts-B-: 40 Nm + 90°
Note:
- Install engine and transmission mountings stress-free.
Drive shaft to flange shaft M8: 40 Nm
Drive shaft to flange shaft M10: 80 Nm
Selector cable spt. brkt to transmission: 25 Nm
Selector cable bolt to transmission selector lever: 25 Nm
Balance weight to transmission selector lever: 25 Nm
Transmission selector lever to transmission: 25 Nm