8.1. Removal and transmission installation

For transmission removal it is necessary to execute following operations:

- To disconnect the storage battery. If the radio receiver with the device on prevention of plunders it is necessary to know a code is established;

- To disconnect a cable of coupling from the lever of deenergizing of coupling as it is described in подразд. 7.4;

Fig. 152. Штекерная колодка the speedometer gauge

- To take out shown on fig. 152 штекерную колодку. It is connected to the speedometer gauge;

Fig. 153. Removed elements at transmission dismantling (are specified by arrows): 1 — штекерная колодка; 2 — a bolt; 3 — the case

- On a transmission to find shown on fig. 153 штекерную колодку 1 switch of a lantern of a backing and to take out it. To turn away a bolt 2 and to disconnect a cable of connection with the case 3. To disconnect the holder штекерной колодки from fastening knot on a transmission;

- To disconnect the power shafts which are on an inside of a transmission, from фланцевых connections as it is described in corresponding subsection. The management mechanism completely to develop to the left, and the left shaft of a drive to fix a cord so that it was as it is possible above;

Fig. 154. Fastening of a finger of a gear change on a transmission: And — a gear change finger; 1 — a bolt; 2 — a place of connection of a cable of a gear change

- To disconnect a finger And (fig. 154) gear changes for what to turn away a bolt 1. To raise and remove a screw-driver a gear change cable between the lever of a gear change and a transmission in a place 2;

Fig. 155. Fastening балансирной transmission suspension brackets: 1 — a nut; 2 — a basic bolt; 3 — fastening bolts; 4 — балансирная a suspension bracket

- Completely to remove балансирную a suspension bracket which is on the bottom party of a transmission. For this purpose it is necessary to turn away a nut 1 (fig. 155) and cautiously to beat out a bolt 2. To turn away three bolts 3 on the bottom party балансирной suspension brackets and to take out a suspension bracket;

- To turn away a support of an inlet collector and to take out it. To uncover the air filter;

- To disconnect from a starter all electric wires and to remove a starter (the section "Electric equipment" see);

Fig. 156. Extraction of the engine from a motor compartment by means of the adaptation

- To take out the engine from suspension brackets. Service centre Volkswagen uses the special adaptation which establish on mudguards, as is shown in fig. 156 for this purpose. If this adaptation is not present, it is necessary to execute following operations:

- To establish a strong steel core between folds of wings over a motor compartment. Enclose under a core a thick layer of rags not to damage metal;

- To wind with a strong wire a steel core and an elevating ear and to braid a wire закруткой in the middle while the engine will not appear under a tension. To watch that thus there was no tension of wires;

Fig. 157. A bolt of fastening of a suspension bracket of a transmission

- To turn away both bolts (fig. 157) and to remove the left suspension bracket of a transmission;

- To bring under a transmission подкатной a jack, to provide a support for the engine and a transmission. Be necessarily convinced that the transmission is reliably kept by a jack. Transmission removal to spend with the assistant;

- To turn out fastening bolts between the engine and a transmission on the bottom party;

- To lower a transmission on a jack. The assistant should operate a jack, moving a transmission. The right party of the engine should be raised, that it was possible to take out a box.

Transmission installation is necessary for spending to sequences, return to removal, taking into account the following:

- To grease шлицевые connections of a cranked shaft by graphite greasing. If the leading shaft of coupling he should be established on шлицы is dismantled and to move to one and other party, to check up ease of a course;

- To check up presence of the landing plugs used for a centering of a transmission on the engine, in the block of cylinders. Otherwise to take out plugs from a transmission and to rearrange them in the block;

- To check up, whether there is an intermediate plate of the engine on landing plugs in the block and whether there is no danger that it will fall;

- To calibrate a carving on a finger of a gear change by means of tap М8. The bolt with which always it is necessary to replace, is processed by a liquid. It protects it from unscrewing and remains on a carving. Therefore at вворачивании a new bolt there can be problems if a carving not to clear;

- New bolt in connection of draught of a plug of switching of a transmission to tighten the moment 20 Нм;

- At transmission installation to be convinced that engine mounts are reliably verified on level. Otherwise after installation it is necessary to spend their centering without pressure;

- To establish балансирную a suspension bracket. To tighten a nut 1 (fig. 155) and a bolt 2 moment 50 Нм and three bolts on the bottom party the moment 25 Нм (if the car is made of 1995) or the moment 35 Нм (since 1996);

- To tighten both bolts specified in fig. by 157 arrows, the left suspension bracket of a transmission the moment 50 Нм;

Fig. 158. An arrangement of bolts of fastening between the engine and a transmission: And, In — installation sites of landing plugs

- To observe the moments of an inhaling specified more low at installation. On fig. 158 the arrangement of bolts of fastening between the engine and a transmission is shown. Not all bolts have identical length.

At installation (fig. 158) it is necessary to tighten bolts following moments, Нм: a bolt 1 (М8х65) — 20; a bolt 2 (М8х70) — 20; a bolt 3 (М8х160) — 20; a bolt 4 (М12х62) — 80; a bolt 5 (М7х12) — 15; a bolt 6 (М12х70) — 80.

- To tighten fastening of a support of an inlet collector by the moment 25 Нм;

- To check up work of the mechanism of adjustment of coupling as it is described in подразд. 7.4;

- To tighten bolts of fastening of power shafts on flanges the moment 45 Нм;

- To tighten a bolt for a gear change finger on draught of a plug of switching of a transmission the moment 20 Нм.

After transmission installation to check up in it oil level if on a transmission works for what to execute the following were spent:

- To establish a forward part of the car on support and to translate the switching mechanism to the left;

- To unscrew from a transmission a stopper маслоналивного the apertures, 159 arrow specified in fig. шестигранный the wrench and a head on 17 mm for this purpose is required. To provide access to a stopper, the universal hinge with надставкой is necessary;

Fig. 159. A stopper arrangement маслоналивного transmission apertures

- To lower in an aperture a finger and to check up, whether there is an oil on the bottom edge маслоналивного apertures;

- After check to screw a stopper and to tighten its moment 25 Нм.

If in a transmission it is necessary to fill in fresh oil the oil syringe which is inserted in маслоналивное an aperture is required. Oil fill in until it will not start to pour out from this aperture. Carefully to clear a stopper and to tighten its moment 25 Нм.