Removing and Installing

Special Tools And Equipment
^ 10-222 A Support
^ 3094 Hose clamps
^ 3282 Transmission support
^ 3282/2 Adjustment plate
^ 3300 A Engine support
^ 3336 Transmission lifting beam





^ VW 457/1 Support rails
^ 10-222 A/1 Support
^ VAG 1331 Torque wrench
^ VAG 1332 Torque wrench
^ VAG 1383 A Engine/transmission jack
^ V/175 Socket

Support Rails, Modifying





To install support rail VW 457/1 to subframe a new hole is required.
Dimensions given are in mm.
- Drill a 8.5 mm (11/32 inch) diameter hole -arrow- in support rail VW 457/1.

Removing
- Obtain radio code
- Disconnect battery ground strap.
- Remove engine cover.
- Remove battery.
- Remove battery support bracket.





Remove air cleaner, if equipped, on left in engine compartment.
- Remove intake hose -1- and connector -2- from Mass Air Flow (MAF) Sensor.
- Remove vacuum hose -3-.
- Remove bolts -4- and -5-.
- Remove air cleaner as complete unit.
- Disconnect speedometer connector at transmission.





- Remove electrical connections -1- to -4- at transmission.
1. To solenoid valves
2. To Vehicle Speed Sensor (VSS) -G68-
3. To Multi-Function Transmission Range (TR) Switch -F125-
4. On Transmission Vehicle Speed Sensor (VSS) -G38-
- Remove wiring harness from retainer on transmission and move to the side.
- Remove bracket for power steering hose with retainer for wiring harness.





- Move selector lever to "P" and pry selector lever cable -1- off lever/selector shaft -4-.

Note:
^ Do not loosen bolt -2-.
^ Do not kink selector lever cable.

- Remove circlip -3- at selector lever cable support bracket and remove selector lever cable.





- Remove (unbolt) ground cable -1- from upper engine/transmission bolt.
- Disconnect electrical connections -3- and -4- on starter,
- Separate connector -2- and pull out of retainer.
- Remove wiring harness retainer on starter.
- Remove upper starter bolt.





- Clamp-off ATF cooler hoses with 3094 and remove at ATF cooler.
- Seal off ATF cooler with clean plugs.
- Remove upper engine/transmission bolts.





- Install support bar 10-222 A with legs 10-222 A/1 and support engine/transmission in this position.
- Remove left front wheel bolts.
- Raise vehicle.
- Remove left wheel.





- Remove noise insulation tray (arrows).





- Remove left noise insulation (arrows).

Vehicles with TDI engine
- Remove line between charge air cooler and exhaust turbocharger.

Continued For All Vehicles
- Remove right noise insulation.





- Remove ATF oil pan protective plate (arrows).





- Remove bracket -1- for power steering pressure line from lower starter bolt -arrow-.
- Remove lower starter bolt
- Remove starter -2-.
- Remove right inner constant velocity joint protective cover from engine if equipped
- Disconnect axle shafts at transmission.
- Raise right axle shaft and secure.





- Remove pendulum support (arrows).
- Remove cap for torque converter nuts cover.





- Remove nut -arrow- from torque converter (Qty. 3) using special tool V 175.
Turn crankshaft 120° for each nut.
- Turn steering to left lock.
- Mark installation position of ball joint bolts on left control arm and remove bolts.





- Remove bolts (arrows).





- Remove left coupling rod -1- from control arm and turn the coupling rod upward.
- Swing wheel bearing housing outward.
- Remove left axle shaft -2- out between sub-frame and transmission.
- Lift axle shaft and fasten to suspension strut with wrench.





- Remove bolts from left assembly mount -2- (arrows) from left console -1-.
- Carefully tilt engine and transmission. Lowering the left-hand spindle approx. 60 mm on support bar 10-222 A will aid in removal.





- Remove left mount -1- from transmission (arrows).
- Separate exhaust system at down pipe, Refer to Exhaust system.





- Bolt support rail VW 457/1 to both pendulum support securing holes on subframe.
- Insert spacers totaling 6 mm be between subframe and support rail VW 457/1.
- -A- Qty. 2 bolts M 8 x 25
- Install support tool 3300 A and tighten with bolt -B-.
- Tilt engine and transmission forward with support tool 3300 A.





- Set up transmission support 3282.

Note:
^ Transmission support 3282 is set up with adjusting plate 328212 for removing automatic transmission 01M.
^ Symbols on adjusting plate indicate supports are required.





- Place jack VAG 1383 A with transmission support 3282 under transmission for support.





- Place safety support pin on oil pan and secure to transmission housing -arrow-.





- On vehicles with triple roller axle shaft turn transmission flange to right until flat -arrow- is vertical.
- Remove lower engine/transmission connecting bolt,
- Separate transmission from engine, while pushing torque converter out of drive plate.
- Push torque converter against ATF pump.
- Lower transmission slightly.
- While lowering transmission, guide power steering pressure line past transmission.
- Tilt transmission using transmission jack spindle and while lowering ensure cover (wheel house side) is guided closely past wheel house.
- Swivel transmission and carefully lower.

Ensure right joint flange does not contact engine or support device 3300 A and multi-function switch does not contact sub-frame.
- Secure torque converter to prevent it falling out.

Installing
Installation is performed in reverse sequence.
When installing torque converter, ensure both drive pins engage in ATF pump inner wheel recesses.
- Before installing, ensure dowel pins line up correctly.
- When installing transmission, observe torque converter pattern on drive plate.
- Replace selector cable anchor lock washer.
- Check selector lever cable adjustment, adjust if necessary refer to Shift Cable, A/T; Adjustments.
- Check and top up ATF level.
- Connect VAG 1551 and check Diagnostic Trouble Code (DTC memory). Refer to Powertrain Management; Computers and Control Systems.

Tightening Torques
Axle Shaft To Flange 40 Nm (30 ft. lbs.)
Torque Converter To Drive Plate 60 Nm (44 ft. lbs.)
Transmission To Engine Bolt M 12 80 Nm (59 ft. lbs.)
Transmission To Engine Bolt M 10 60 Nm (44 ft. lbs.)
Transmission To Oil Pan/Engine M 10 25 Nm (18 ft. lbs.)
Ball Joint To Control Arm 35 Nm (26 ft. lbs.)
Coupling Rod To Control Arm 45 Nm (33 ft. lbs.)
Wheel Bolts To Wheel Hub 120 Nm (89 ft. lbs.)





Transmission to body
Bolts -A- 60 Nm + 90 degrees (44 ft. lbs. + 90 degrees)
Bolts -B- 40 Nm + 90 degrees (30 ft. lbs. + 90 degrees)

- Replace bolts





Rear transmission mounting
Bolts -A- 20 Nm + 90 degrees (15 ft. lbs. + 90 degrees)
Bolts -B- 40 Nm + 90 degrees (30 ft. lbs. + 90 degrees)

- Replace bolts -B-.

Note:
^ Install engine/transmission mounts stress-free. Refer to Engine.

Automatic Transmission, Transporting
Special tool 3336 may be used to transport the automatic transmission and also when setting up transmission support 3282.





- Secure special tool 3336 to transmission housing flange.
- Position pins so that 8 holes are visible in chain direction.