Support rails VW 457/1, modifying: Removing

WARNING: This page does not describe the selected car, but rather 20 other vehicles, including the 2007 Volkswagen Golf, 2006 Volkswagen Golf, 2005 Volkswagen Jetta, 2005 Volkswagen Golf, and 2004 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Obtain radio code on vehicles with coded radio.
Disconnect battery ground strap.
Remove engine cover.
Remove battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL , Battery Removing and Installing

Remove battery carrier.

Fig 1: Locating Battery Carrier Bolts

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Remove screws (arrows) and remove battery carrier. When installing, tighten bolts to 6 Nm.

Fig 2: Identifying Air Cleaner Housing & Components

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Remove air cleaner if installed on left in engine compartment:
Pull intake hose -1- and connector -2- off mass air flow sensor.
Pull off vacuum hose -3- if installed.
Remove bolts -4- and -5-.

Remove air cleaner complete.
Disconnect connector for Speedometer vehicle speed sensor -G22- at transmission.

Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations

Fig 3: Identifying Transmission Electrical Connections

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Remove electrical connections -1- to -4- at transmission.

1 - To the solenoid valves

2 - To Vehicle speed sensor -G68-

3 - To Multi-function TR switch -F125-

4 - On Transmission vehicle speed sensor -G38-

There are two types of -G38- sensor. Connection with and without cable.

Remove wiring harness from retainer on transmission and place to one side.
Remove bracket for power steering hose with retainer for wiring harness.

Fig 4: Identifying Lever/Selector Shaft, Ball Mounting, Circlip & Bolt

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Place selector lever in "P" and pry selector lever cable -1- off lever/selector shaft -4- with a screwdriver.

NOTE: Do not loosen bolt -2-.

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

NOTE: Do not kink selector lever cable.

Fig 5: Identifying Battery Ground Cable, Connector & Electrical Connections

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Disconnect battery ground cable -1- from upper engine/transmission securing 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 motor bolt.

Fig 6: Clamping Off ATF Cooler Hoses With Clamps 3094

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Clamp off ATF cooler hoses with clamps 3094 and disconnect at ATF cooler.
Seal off ATF cooler with clean plugs.
Remove engine/transmission upper securing bolts.

Fig 7: Mounting Support 10-222A With Legs 10-222A/1

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

NOTE: If the bolts are removed before the vehicle is raised, the wheel is not fastened and could cause a dangerous situation.

Raise vehicle.
Remove front left wheel bolts and remove front left wheel.

Vehicles with TDI engine

Fig 8: Identifying Noise Insulation Tray & Bolts

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Remove sound insulation cover (arrows).

Vehicles with 1.8 ltr. turbo and 2.0 ltr. engines

Remove sound insulation cover:

Refer to 50 BODY, FRONT

Fig 9: Locating Left Sound Insulation & Bolts

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Remove left sound insulation cover (arrows).

Vehicles with TDI and 1.8 ltr. turbo engines

Remove line between charge air cooler and exhaust turbocharger.

Continued for all vehicles

Remove right sound insulation cover.

Fig 10: Identifying ATF Oil Pan Protective Plate Bolts

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Remove ATF oil pan protective plate (arrows).

Fig 11: Identifying Power Steering Pressure Line Bracket, Starter & Lower Starter Bolt

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Remove bracket -1- for power steering pressure line from lower starter bolt (arrow).
Remove lower starter bolt
Remove starter -2-.

Continued for all vehicles

Remove right hand inner constant velocity joint protective cover from engine if installed.
Disconnect axle shafts at transmission flanges.
Raise right axle shaft and secure.

Fig 12: Identifying Pendulum Support & Bolts

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

Fig 13: Identifying Torque Converter Nut

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Remove nut (arrow) from torque converter (Qty. 3) using special tool V 175.

Turn crankshaft 120 ° further in each case.

Turn steering to left lock.
Mark installed position of ball joint bolts on left-hand control arm (arrows).

Fig 14: Removing Bolts

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Remove bolts.

Fig 15: Identifying Coupling Rod & Axle Shaft

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Disconnect left coupling rod -1- from control arm and turn coupling rod upward.
Swing wheel bearing housing outward.
Guide left axle shaft -2- out between subframe and transmission.
Lift axle shaft and secure to suspension strut with wire.

Fig 16: Identifying Assembly Mounting, Hex Bolts & Mount Support

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Remove left assembly mounting -2- hex bolts (arrows) from mount support -1-.
Carefully tilt engine and transmission by lowering left-hand spindle approx. 60 mm on support bar 10-222 A.

Fig 17: Identifying Mount Support & Transmission

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Remove left mount support -1- from transmission (arrows).
Separate exhaust system at exhaust manifold connection.

Refer to 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP, 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH, 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW, 26 EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 2V ENGINE MECHANICAL, FUEL INJECTION & IGNITION, ENGINE CODE(S): AEG, AVH, AZG, BBW, BEV, 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.8 LITER VR6 2V ENGINE MECHANICAL, ENGINE CODE (S): AFP, 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.8 LITER VR6 4V ENGINE MECHANICAL, ENGINE CODE(S): BDF and 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 LITER VR6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BJS ; Removing and installing parts of exhaust system.

Fig 18: Identifying Support Rail VW 457/1, Support Device 3300 A & Bolts

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Bolt support rail VW 457/1 to both pendulum support securing holes on subframe.
Insert spacers totalling 6 mm thick between subframe and support rail VW 457/1.

-A- Qty. 2 hex bolts M 8 x 25

Mount support device 3300 A and tighten with bolt -B-.
Tilt engine and transmission forward with support device 3300 A.

Fig 19: Transmission Support 3282 Set Up With Adjusting Plate 3282/2

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Set up transmission support 3282.

The transmission support 3282 is set up with the adjusting plate 3282/2 for removing the automatic transmission 01M.

The symbols on the adjusting plate indicate the supports required.

Fig 20: Jack V.A.G 1383 A With Transmission Support 3282 Under Transmission

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Move jack V.A.G 1383 A with transmission support 3282 under transmission and support it.

Fig 21: Placing Safety Support Pin On Oil Pan And Secure To Transmission Housing

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

Fig 22: Identifying Transmission Flange Flat

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On vehicles with triple roller drive shaft turn transmission flange to right so that flat (arrow) is vertical.
Remove lower engine/transmission connecting bolt.
Press transmission off engine, when doing this, press torque converter out of drive plate.
Press torque converter against ATF pump.

Lower transmission slightly and guide power steering pressure line past transmission.
Tilt transmission using transmission jack spindle and while lowering ensure cover (wheel housing side) is guided closely past wheel housing.
Swivel transmission and carefully lower.

NOTE: Ensure that the right joint flange does not contact the engine or the support device 3300 A and that the multi-function TR switch does not contact the subframe.

Secure torque converter to prevent it from falling out.