Modifying support rails VW 457/1: Removing

WARNING: This page is about a different variant/trim than selected.

Remove cover from engine.

NOTE: Check whether a coded radio is installed as during the forthcoming work sequences the battery ground strap must be disconnected. Obtain radio code first if necessary.

With ignition switched off disconnect battery ground strap.

Fig 1: Identifying Air Cleaner Housing & Components

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Remove intake hose -1- , connector -2- and hose -3- from mass air flow sensor.
Remove complete air cleaner housing by unscrewing bolts -4- and -5-.

Refer to 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWD, 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): AWW, AWP, 24 MULTIPORT FUEL INJECTION (MFI) for 2.0 LITER 4-CYL. 2V ENGINE MECHANICAL, FUEL INJECTION & IGNITION, ENGINE CODE(S): AEG, AVH, AZG, BBW, BEV, 24 MULTIPORT FUEL INJECTION (MFI) for 2.8 LITER VR6 2V FUEL INJECTION IGNITION, 24 MULTIPORT FUEL INJECTION (MFI) for 2.8 LITER VR6 4V FUEL INJECTION IGNITION and 24 - MULTIPORT FUEL INJECTION (MFI) for 3.2 LITER VR6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BJS

Transmissions up to 05.99

Fig 2: Identifying Vehicle Speed Sensor & Reverse Light Connectors (Up To 05.99)

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Pull connector off vehicle speed sensor (arrow -1-).
Disconnect reverse light connector (arrow -2-).

Fig 3: Identifying Balance Weight, Gear Selector Cable & Actuating Arm/Relay Lever

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Remove balance weight -A- and gear selector cable -B- from gear selector lever.
Remove gear selector cable with washer and square nut (self-locking).
Lift tab in direction of arrow and pull gate selector cable off actuating arm/relay lever -C-.

Fig 4: Cable Support Bracket Bolts

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Remove cable support bracket from transmission (arrows). If necessary unclip hose at cable support bracket first.

Fig 5: Identifying Slave Cylinder

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Remove slave cylinder place to side and secure with wire, do not disconnect lines.

NOTE: Do not depress clutch pedal.

Fig 6: Identifying Cable Retainer & Upper Securing Bolt

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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 engine/transmission upper securing bolts.

Transmissions from 05.99

Fig 7: Cable Support Bracket Bolts

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Remove cable support bracket from transmission (arrows). If necessary unclip hose at cable support bracket first.

Fig 8: Identifying Gate Selector Cable, Gear Selector Cable & Nut

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Remove circlip and pull off gate selector cable -A- with relay lever.
Remove nut (arrow) and remove gear selector cable -B- with transmission selector lever.
Tie selector cable with transmission selector lever and gate selector cable with relay lever up.

Fig 9: Identifying Vehicle Speed Sensor & Reverse Light Connector (From 05.99)

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Disconnect connector from vehicle speed sensor (arrow -1-).
Disconnect reverse light connector (arrow -2-).

Fig 10: Identifying Slave Cylinder

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Remove slave cylinder and place to side, secured with wire. Do not disconnect hydraulic lines.

NOTE: Do not depress clutch pedal.

Fig 11: Identifying Cable Retainer & Upper Securing Bolt On Starter

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Remove cable retainer (arrow -1-) on starter.
Remove wiring and cable from starter.
Remove ground strap at engine/transmission upper securing bolt.
Remove upper securing bolt (arrow -2-) on starter.

Remove engine/transmission upper securing bolts.
If there are hoses and cable connections in area of engine mounting eye for support 10-222A, remove these now.

Fig 12: Mounting Support 10-222A With Legs 10-222A/1

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Continued for vehicles with 4-Cyl. engine

Fit support bar 10-222A together with legs 10-222 A/1.

Continued for vehicles with 6-Cyl. engines

Fit support bar 10-222A together with legs 10-222 A/1 and adapters 10-222 A/3.

Fig 13: Mounting Support 10-222A With Adapters 10-222 A/3

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Continued for all vehicles

Take weight of engine/transmission assembly on spindles.
If fitted, remove center and left part of insulation tray below engine/transmission.
Remove power steering line from starter and transmission.
Remove starter.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Remove right hand inner constant velocity joint protective cover from engine if fitted.
Turn wheels fully onto left lock.
Disconnect drive shafts from flanged shafts and tie up as high as possible. Do not damage surface protection of parts.

Fig 14: Flywheel Small Cover Plate Behind Right-Hand Flanged Shaft

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Remove flywheel small cover plate -A- behind right-hand flanged shaft (arrows), if fitted.
Remove lower flywheel cover plate, if part of original equipment.
Separate exhaust system and if necessary remove from subframe.

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

Fig 15: Identifying Pendulum Support & Bolts

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Remove pendulum support (arrows -A- and -B-).

Fig 16: Identifying Transmission Support & Hex Bolts

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Remove transmission support (arrow -A-) from transmission.
Remove hex bolts (arrows -B-) from left-hand hand assembly mounting.
Incline engine/transmission assembly by lowering it via left spindle of support bar 10-222A.

The transmission mount -A- securing bolts (arrows) must be accessible.

Fig 17: Identifying Transmission Mount

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Remove transmission mount -A- (arrows).

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

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

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

Fit support 3300 A and secure (arrows).

Vehicles with 5 valve engine

Fig 19: Identifying Support 3300 A

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Remove a lower engine/transmission securing bolt so that support 3300 A can be installed.

The support 3300 A must be installed directly next to the transmission on the engine.

Continued for all vehicles

Press engine/transmission forward carefully.

NOTE: Do not damage power steering line when moving engine/transmission assembly.

Assemble transmission jack with transmission support 3282, adjustment plate 3282/8 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 transmission support according to holes in adjustment plate.

Fig 20: Identifying Support Elements & Symbol On Adjustment Plate

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Bolt support elements -A-, as illustrated, on adjustment plate.

Fig 21: Transmission Jack Positioned Under Vehicle

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Place transmission jack under vehicle. Arrow symbol -B- (Refer to Fig 20 ) 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.

Fig 22: Inclining Transmission With Spindles Of Transmission Support 3282

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Press transmission off dowels and carefully swing towards subframe.
Lower transmission slightly and incline to left via spindles of transmission support 3282.

Fig 23: Right-Hand Flange Shaft In Area Of Flywheel & Left-Hand Flange Shaft In Area Of Subframe

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Lower transmission carefully guiding right-hand flange shaft -A- in area of flywheel as illustrated. Guide left-hand flange shaft -B- in area of subframe.

NOTE:

When lowering, change position of transmission using the transmission support 3282 spindles.
Do not damage power steering line when lowering transmission.