Jetta Sportwagen (US)/Golf Wagon (Canada) From MY 10, With A Diesel Engine
Transmission, Removing
Special tools, testers and auxiliary items required
• Engine Support Bridge (10-222 A)
• Engine Support Feet (10-222 A/8)
• Engine Support Adapter (10-222 A/3)
• Adapter (10-222 A/18)
• Transmission Support (3282)
• Support Elements (Pins) (2382/29)
• Adjustment Plate (3282/33)
• Transmission Support Jig (3336)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Engine/Transmission Jack (V.A.G 1383 A)
• Bracket (T10346)
• Engine Support Device (3300 A)
• Adapter (VW 771/40)
• Hose Clamps up to 25 mm Dia. (3094)
• Grease for Clutch Plate Splines (G 000 100)
• Grease (G 000 450 02)
• M6 x 20 Bolt
• M6 x 80 Bolt
• M10 x 20 Bolt
The engine support bridge (10-222 A) and the engine support feet (10-222 A/8) will be mounted on the longitudinal members later in the procedure.
• To protect the edges of the fender, cover both engine support feet (10-222 A/8) with cloth tape - arrow -. Refer to the Parts Catalog.
- See if a coded radio is installed, If so, obtain the anti-theft code.
- Turn off the ignition and disconnect the battery ground cable.
Later in the procedure, the engine support bridge (10-222 A) is connected to the engine lifting eyes.
- Remove the engine cover, if it is blocking the lifting eyes.
- Remove the air filter housing if it is located near the battery.
- Remove the battery, the battery cover and the battery tray.
- Remove the shift cable lock washer - 3 - from the transmission shift lever - 1 - and remove the cable from the pin - arrow -.
with a Metal Relay Lever
- Remove the selector cable lock washer - 4 - from the relay lever - 2 - and remove the cable from the pin - arrow -.
with a Plastic Relay Lever
- Remove the cable retainer from the selector cable.
• To avoid damage to the selector cable, the cable retainer must be disconnected from the selector lever before removal.
- Pull the locking mechanism all the way forward in the - direction of arrow 1 - and then unlock it to the left in the - direction of arrow 2 -.
- Press the relay lever forward, in the - direction of arrow 3 -.
- The relay lever is removed together with the cable retainer later in the procedure.
- Remove the cable bracket bolts/nut - arrows - from the transmission, move it to the side and secure it.
with a Pipe between the Clutch Master and Slave Cylinders
- Clamp off the supply hose to the master cylinder using a hose clamp up to 25 mm dia. (3094).
with a Hose/Line Assembly between the Clutch Master and Slave Cylinders
- Clamp off the hose on the hose/line assembly - A - to the clutch slave cylinder using a hose clamp up to 25 mm dia. (3094).
Continuation for All
- Pull the clip - arrow - for the hose/line assembly or the pipe out all the way to the stop.
- Remove the hose/line assembly or pipe from the breather assembly and plug it.
Do not press the clutch pedal anymore.
- Remove the ground strap - 1 - from the upper starter stud bolt.
- Disconnect the connector - 2 - from the backup lamp switch.
- Disconnect the connector and the wire from the starter.
- Remove the upper engine to transmission stud bolts - arrows -.
- Remove the upper bolt from the starter.
- Install the bracket (T10346) to the rear most hole out of the three holes for the battery tray.
- Use a M6 x 80 bolt with a collar or one of the battery tray bolts for this.
- Disconnect any hoses and wires in the area of the engine lifting eyes.
- Install the engine support bridge (10-222 A) in front of the engine hood support.
- Use the following special tools:
• Engine support adapter (10-222 A/3)
• Engine support feet (10-222 A/8)
• Adapter (10-222 A/18)
- Position the adapter (10-222 A/8) :
• On the upper longitudinal members, directly in front of the ridge (- arrow 1 -) next to the bolt (- arrow 2 -)
- Then, attach engine support bridge to the bracket (T10346).
- Hook the spindle into the left lifting eye on the engine.
- Pretension the engine and transmission using the engine support bridge and spindles.
The left drive axle bolt - arrow - must be removed later in the procedure.
- With the vehicle still resting on its wheels, loosen the left front drive axle bolt - arrow - a maximum of 90° (1/4) , otherwise the wheel bearing will be damaged.
- Remove the noise insulation.
- Remove the lower part of the left front wheel housing liner.
- Remove the left front vehicle level control system sensor from the control arm, if equipped.
- Remove the wiring bracket from the starter.
- Remove the starter.
- Remove the left charge air hose - arrows 1 and 2 -
- Remove the charge air pipe from the engine.
- Remove the right charge air hose from the charge air cooler.
- Remove the fan shroud - arrow - and the coolant fans.
- Remove the exhaust system suspended mount bolts - arrows - from the subframe.
- Disconnect the exhaust system at the double clamp - arrows -.
- Tie up the front exhaust pipe or lay it on the tunnel brace.
- Remove the pendulum support.
- Disconnect the oil level thermal sensor connector - 1 -.
- Remove the coupling rod from the stabilizer bar and move it to the side.
- Remove the left drive axle.
- Remove the right drive axle heat shield bolts - arrows - and shield, if equipped.
- Remove the right drive axle from the transmission and tie it up.
- Remove the engine mount - 2 - to engine mount bracket bolts - arrows - from the left bracket.
- Lower the transmission approximately 40 mm - a - using the spindles, which are attached to the engine.
• When lowering the engine and transmission assembly, pay attention to any connected lines, hoses and the radiator.
- Remove the transmission mount bracket - 1 - to transmission bolts - arrows -.
with a Metal Relay Lever
- Remove the lock washer - arrow - from the relay lever - 1 - and then remove the relay lever.
with a Plastic Relay Lever
- Remove the relay lever with the cable retainer. Refer to => [ Plastic Relay Lever ] 02Q Manual Transmission.
Continuation for All
- Remove the transmission shift lever from the gear shift shaft.
- Remove the small flywheel cover plate - A - - arrows -, if equipped.
- Remove the engine to transmission bolt - 1 -.
• Loosen the engine and transmission bolt - 3 - and leave it in hand tight.
- install the bracket (T10346) with the bolt - 1 - to the left threaded hole in the subframe.
- 1 - = M6 x 20 collar bolt
- Install the engine support device (3300 A) to the bracket (T10346).
- Place a cloth between the engine support device (3300 A) and the oil pan.
- Push the engine forward using the spindle on the engine support device (3300 A). Note the following when doing this:
• The (A/C) Air Conditioning compressor - 2 - must not touch the refrigerant line - 1 - - arrow -.
• The generator must not touch the refrigerant line.
• The pressure pipe must not touch the radiator.
To remove the transmission, the adjustment plate (3282/33) must be installed on the transmission support (3282).
- Install the transmission support (3282) onto the engine-/gearbox jack (V.A.G 1383 A).
- Align the arms of the transmission support so that they match up with the holes in the adjustment plate.
- Install the support elements - A - as illustrated on the adjustment plate.
- Install the pins in place on the adjustment plate - C -.
- Position the engine-/gearbox jack (V.A.G 1383 A) under the vehicle. The arrow symbol - B - on the adjustment plate points in the direction of travel.
- Align the adjustment plate so that it is parallel to the transmission.
- Secure the adapter for VW 771 slide hammer (VW 771/40) into the threaded hole in the transmission housing as illustrated.
- Install the pin (3282/29) into the hole on the transmission for the pendulum support bolt.
- Secure the transmission to the transmission support (3282) with an M10 x 20 bolt - A -.
The arm - B - must be flush with the guide on the transmission support (3282) - arrow -.
The engine and transmission bolt - arrow - is removed.
- Remove the engine to transmission bolt - C - and the lower engine to transmission bolts.
- Separate the transmission from the engine (alignment sleeves).
- Move the transmission in the area of the differential with the transmission support (3282) spindles into an angled position.
• The differential, near the transmission, must face upward.
The right flange shaft - 1 - must be guided over the cylinder block bolt flange - 2 -.
- Guide the transmission and the differential over the subframe - A - and swing it out.
- Pay attention to the longitudinal member - arrows -. Then carefully lower the transmission.
• Pay attention to the lines when lowering the transmission.