2003 Volkswagen Passat GL

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1 AUTOMATIC TRANSMISSIONS Removal & Installation - 01V APPLICATION TRANSAXLE APPLICATION Application Transaxle Model Passat 1.8L (FWD) 01V 2.8L (FWD & 4WD) 01V 4.0L (AWD) V REMOVAL & INSTALLATION 1.8L Removal & Installation NOTE: NOTE: CAUTION: In the following procedures, letters and numbers in parenthesis are shown in illustrations. When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. Radio/cassette or radio/cd player is equipped with an anti-theft protection circuit. Whenever battery is disconnected, radio will go into anti-theft mode. When battery is reconnected, radio will display CODE, and will be inoperative until proper code number is entered. Obtain security code before disconnecting battery. 1. Disconnect negative battery cable. Remove engine cover. Assemble Adapter ( A/3) for front spindle on Support Bar ( A). Position Support Bar ( A) with Legs ( A/1) and support engine/transaxle in this position. See Fig. 1. Loosen drive axle/wheel hub bolt and wheel bolts. Raise and support vehicle. Remove front wheels. Remove drive axle/wheel hub bolt. 2. Remove noise insulation tray. Remove noise insulation tray bracket. Remove left and right axle shaft noise insulation from wheel housing (arrows). See Fig. 2. Remove right axle shaft protective plate. Remove drive axles. Pull connector (1) off wire for multifunction TR switch. Turn locking lever (2) and unplug connector for transaxle wiring harness. See Fig. 3. Disconnect speedometer sender connector at transaxle. 3. Mark position of support bracket for securing selector lever cable to transaxle housing (position must be correct when installing). Unbolt support bracket (arrows). See Fig. 4. Remove front exhaust pipe. Remove ATF lines from engine/transaxle assembly (arrows) and secure to the side. See Fig. 5. Plug ATF lines with clean plugs. 4 января 2005 г. 0:01:49 Page Mitchell Repair Information Company, LLC.

2 Fig. 1: Installing Support Bar & Adapter To Engine/Transaxle Assembly 4 января 2005 г. 0:01:50 Page Mitchell Repair Information Company, LLC.

3 Fig. 2: Removing Noise Insulation From Wheel Housing 4 января 2005 г. 0:01:50 Page Mitchell Repair Information Company, LLC.

4 Fig. 3: Removing Multifunction TR Switch Connector & Wiring Harness Connector 4 января 2005 г. 0:01:50 Page Mitchell Repair Information Company, LLC.

5 Fig. 4: Removing & Installing Support Bracket Bolts 4 января 2005 г. 0:01:50 Page Mitchell Repair Information Company, LLC.

6 Fig. 5: Removing ATF Lines From Engine/Transaxle Assembly 4. Remove selector lever cable from selector shaft lever (arrow). See Fig. 6. Remove starter. Unbolt torque converter from drive plate using Special Socket (V 175). See Fig. 7. Remove lower engine/transaxle bolts. 5. Set up Transaxle Support (3282). Transaxle Support (3282) is set up with Adjusting Plate (3282/19) for transaxle removal. Symbols on adjusting plate indicate mounts required, and arrow points forward. See Fig Move Transaxle Jack (VAG 1383 A) with Transaxle Support (3282) under the transaxle and support transaxle. Align adjusting plate parallel with transaxle. Secure transaxle to Transaxle Support (3282) with bolt (A). See Fig NOTE: If holes are not aligned in the following step, check wheel alignment measurements after tightening subframe. Remove right bonded rubber mount protective plate (1) on transaxle support. Remove right transaxle support (3) with bonded rubber mount (2). See Fig. 10. Remove left transaxle support with bonded rubber mount. Before loosening the subframe ensure holes (1) and (2) align on both sides of vehicle using Mandrel (3393). See Fig января 2005 г. 0:01:50 Page Mitchell Repair Information Company, LLC.

7 8. Remove bolts (1) and (2) at rear of subframe on both sides of vehicle. Remove bolts (3) at front of subframe on both sides of vehicle. Loosen each bolt (4) (2 on each side of vehicle) 3 full turns. See Fig. 12. When the bolts are loosened, the rear of the subframe will drop about 5.91" (150 mm). See Fig Lower rear of engine/transaxle assembly slightly with Transaxle Jack (VAG 1383 A). Remove upper engine/transaxle connecting bolts. Press transaxle off engine and at the same time, press torque converter out of drive plate. 10. Press torque converter against ATF pump (arrow). See Fig. 13. Secure torque converter to keep it from falling out. Swivel transaxle (arrow) and carefully guide out between subframe and underbody. See Fig. 14. Lower transaxle. Fig. 6: Removing Selector Lever Cable From Selector Lever Shaft 4 января 2005 г. 0:01:50 Page Mitchell Repair Information Company, LLC.

8 Fig. 7: Unbolting Torque Converter From Drive Plate 4 января 2005 г. 0:01:50 Page Mitchell Repair Information Company, LLC.

9 Fig. 8: Setting Up Transaxle Support & Adjusting Plate 4 января 2005 г. 0:01:50 Page Mitchell Repair Information Company, LLC.

10 Fig. 9: Securing Transaxle To Transaxle Support 4 января 2005 г. 0:01:50 Page Mitchell Repair Information Company, LLC.

11 4 января 2005 г. 0:01:50 Page Mitchell Repair Information Company, LLC.

12 Fig. 10: Removing Protective Plate, Mount & Transaxle Support Fig. 11: Checking Subframe Alignment 4 января 2005 г. 0:01:50 Page Mitchell Repair Information Company, LLC.

13 Fig. 12: Removing Subframe Bolts 4 января 2005 г. 0:01:50 Page Mitchell Repair Information Company, LLC.

14 Fig. 13: Pressing Torque Converter Against ATF Pump 4 января 2005 г. 0:01:50 Page Mitchell Repair Information Company, LLC.

15 Fig. 14: Lowering Transaxle Between Subframe & Underbody 11. NOTE: CAUTION: Prior to installing transaxle, clean ATF lines. See SERVICING - A/T article. Ensure dowel sleeves and intermediate plate are correctly positioned on engine. Ensure that torque converter seats correctly in transaxle. If the torque converter is in incorrect installation position, the follower of the converter or ATF pump will be destroyed when the transaxle is connected to the engine. Push on torque converter hub to first stop at oil seal. Turn torque converter inward using light pressure until opening in hub engages with follower of pump sprocket and until torque converter can be felt to slip in place. Using depth gauge, measure converter installed distance. If the converter is correctly positioned, the distance between the contact surfaces below at the tapped holes in the converter and the contact surface of the converter housing of transaxle will be about.91" (23 mm). See Fig. 44. If 4 января 2005 г. 0:01:50 Page Mitchell Repair Information Company, LLC.

16 the converter is not correctly positioned, the distance is about.43" (11 mm). 12. Set up Transaxle Support (3282). Transaxle Support (3282) is set up with Adjusting Plate (3282/19) for transaxle installation. Symbols on adjusting plate indicate mounts required, and arrow points forward. See Fig Place transaxle on transaxle jack. Secure transaxle to Transaxle Support (3282) with bolt (A). See Fig. 9. Place transaxle jack under vehicle. Guide transaxle in between lowered subframe and underbody. At this stage the subframe is lowered about 5.91" (150 mm) at the rear. See Fig Align transaxle to engine. Install upper engine/transaxle bolts. Raise rear of engine/transaxle assembly slightly using Transaxle Jack (VAG 1383 A). Secure subframe. Install left transaxle support with bonded rubber mount. See Fig Install right transaxle support (3) with bonded rubber mount (2). Install right bonded rubber mount/protective plate (1) to transaxle support. See Fig. 10. Install lower engine/transaxle bolts. Remove bolt (A) after transaxle is bolted to engine. See Fig. 9. Apply anti-corrosion compound to point of contact between bolt (A) and oil pan. Install torque converter and drive plate together using Special Socket (V 175). See Fig. 7. Install starter. 16. Install drive axles. Install right drive axle protective plate. Install ATF lines to engine/transaxle assembly. Move selector lever to "P" position and push selector lever cable on selector lever shaft. Install bolts to support bracket for selector lever cable and install selector lever cable. See Fig Plug connector on multifunction TR switch (1). Install connector for transaxle wiring harness and secure with locking lever (2). See Fig. 3. Reconnect speedometer sender connector. Install front exhaust pipe. 18. Install left and right axle shaft noise insulation to wheel house. See Fig. 2. Install noise insulation tray bracket. Install noise insulation tray. Install front wheels. Remove Support Bar ( A). Install engine cover. Reconnect negative battery cable. Check selector lever cable adjustment. With transaxle installed, check final drive oil level. Check and top off ATF level. See SERVICING - A/T article. 19. Tighten transaxle housing bolts in crisscross pattern to specification. See TRANSAXLE-TO- ENGINE BOLT TORQUE SPECIFICATIONS (1.8L) table. For bolt locations, see Fig. 15. Always replace subframe-to-body, and axle shaft-to-wheel hub bolts. For bolt and nut tightening specifications, see TORQUE SPECIFICATIONS. TRANSAXLE-TO-ENGINE BOLT TORQUE SPECIFICATIONS (1.8L) Bolt No. Bolt Size Ft. Lbs. (N.m) 01V (1.8L) (1) 1 M 12 X (65) 2 M 12 X (65) 3 M 12 X (65) 4 (With Nut) M 10 X (45) 5 M 10 X (45) (1) For bolt locations, see Fig января 2005 г. 0:01:50 Page Mitchell Repair Information Company, LLC.

17 Fig. 15: Transaxle-To-Engine Bolt Identification (Passat 1.8L) 2.8L Removal & Installation NOTE: NOTE: In the following procedures, letters and numbers in parenthesis are shown in illustrations. When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. 4 января 2005 г. 0:01:50 Page Mitchell Repair Information Company, LLC.

18 CAUTION: Radio/cassette or radio/cd player is equipped with an anti-theft protection circuit. Whenever battery is disconnected, radio will go into anti-theft mode. When battery is reconnected, radio will display CODE, and will be inoperative until proper code number is entered. Obtain security code before disconnecting battery. 1. With ignition switch turned off, disconnect negative battery cable. Unscrew bolts (arrows) and remove engine cover. See Fig. 16. Take intake hose off intake manifold. 2. Install Support Bar ( A) together with Support Legs ( A/1) and Adapters ( A/3). Secure spindles to engine. In addition, use a Shackle ( A/12) on the front of the engine to avoid damage. See Fig. 17. Place weight of engine/transaxle assembly on the spindles. Loosen wheel bolts. Raise and support vehicle. Remove front wheels. Remove noise insulation tray (arrows). See Fig. 18. Remove front exhaust system with catalytic converter. 3. Remove protective plate and bolts (arrows) for left and right hand drive axles. The third bolt cannot be seen in the illustration. Disconnect left and right hand drive axles (1) from flanges and secure to the side. See Fig. 19. Remove noise insulation tray bracket (1). Pull connector (2) off multifunction TR switch lead. Turn locking lever (3) and remove connector for transaxle wiring harness. Cut cable tie (4). See Fig января 2005 г. 0:01:50 Page Mitchell Repair Information Company, LLC.

19 Fig. 16: Removing Engine Cover 4 января 2005 г. 0:01:51 Page Mitchell Repair Information Company, LLC.

20 Fig. 17: Installing Support Bar Assembly 4 января 2005 г. 0:01:51 Page Mitchell Repair Information Company, LLC.

21 Fig. 18: Removing & Installing Noise Insulation Tray 4 января 2005 г. 0:01:51 Page Mitchell Repair Information Company, LLC.

22 Fig. 19: Removing Protective Plates & Drive Axle 4 января 2005 г. 0:01:51 Page Mitchell Repair Information Company, LLC.

23 Fig. 20: Disconnecting Wiring Connections 4. Pull connector off speedometer sender (arrow A). Unscrew engine speed (RPM) sensor (arrow B) from transaxle. See Fig. 21. Remove ATF line holder (arrow) from engine oil pan. See Fig. 22. Place drain pan underneath ATF lines/cooler. 5. Thoroughly clean area around ATF line/transaxle. Separate ATF lines (1) to ATF cooler. Seal off ATF lines with clean plugs. Do not remove ATF line holder (3). Remove transaxle side starter bolt (2). See Fig. 23. Remove starter. Unbolt torque converter from drive plate (3 securing nuts). See Fig. 24. Turn crankshaft 1/3 turn for each nut. 6. On 4WD vehicles, remove heat shield (A) from vehicle underbody. Remove cover plate (B) bolts (arrows). See Fig. 25. Mark drive shaft position at transaxle for reassembly reference. Disconnect drive shaft from transaxle. Push drive shaft back onto stop and secure in this position. 7. On all models, mark position of support bracket for securing selector lever cable to transaxle housing (position must be correct when installing). Unbolt support bracket (arrows). See Fig. 4. Remove selector lever cable from selector shaft lever (arrow). See Fig. 6. Remove side and lower engine/transaxle connecting bolts. 4 января 2005 г. 0:01:51 Page Mitchell Repair Information Company, LLC.

24 8. Set up Transaxle Support (3282). Transmission Support (3282) is set up with Adjusting Plate (3282/19) for transaxle removal. The symbols on the adjusting plate indicate the mounts required, and the arrow points forward. See Fig. 8. Move Transaxle Jack (VAG 1383 A) with Transaxle Support (3282) under the transaxle, align adjusting plate parallel to transaxle and support transaxle. Secure transaxle to Transaxle Support (3282) with bolt (A). See Fig. 9. Chock space between transaxle support and oil pan using washers. Fig. 21: Disconnecting Speedometer Sender & RPM Sensor 4 января 2005 г. 0:01:51 Page Mitchell Repair Information Company, LLC.

25 Fig. 22: Removing ATF Line Holder From Oil Pan 4 января 2005 г. 0:01:51 Page Mitchell Repair Information Company, LLC.

26 Fig. 23: Separating ATF Lines & Removing Starter Bolt 4 января 2005 г. 0:01:51 Page Mitchell Repair Information Company, LLC.

27 Fig. 24: Removing Torque Converter Nuts 4 января 2005 г. 0:01:51 Page Mitchell Repair Information Company, LLC.

28 Fig. 25: Removing Heat Shield & Cover Plate At Drive Shaft (4WD & AWD) 9. NOTE: If holes are not aligned in the following step, check wheel alignment measurements after tightening subframe. Remove left and right hand engine mounting nuts (1). Remove bolts (2) from transaxle mounting to subframe. See Fig. 26. Before loosening the subframe, it is essential to check that holes (1) and (2) are aligned on both sides of the vehicle using Mandrel (3393). See Fig. 11. Hole (3) has does not require checking. 10. Unscrew bolts (1) and (2) at rear of subframe on both sides of vehicle. Remove bolts (3) at front of subframe on both sides of vehicle. Remove bolts (4) (2 on each side of vehicle). See Fig. 12. Take note when lowering the transaxle that no components are damaged. 11. Lower engine/transaxle assembly 8 turns on spindles. Lower engine/transaxle assembly in stages, alternating on each spindle 2 turns at a time. See Fig. 17. At the same time, lower engine/transaxle 4 января 2005 г. 0:01:51 Page Mitchell Repair Information Company, LLC.

29 assembly on Transaxle Jack (VAG 1383 A), with aid of an assistant. Remove upper engine/transaxle connecting bolts. Press transaxle off engine, and at the same time press torque converter out of drive plate. 12. Press torque converter against ATF pump (arrow). See Fig. 13. Lower transaxle. Secure torque converter to prevent it from falling out. When working on the transaxle, torque converter must be secured to the repair stand with Transport Device (3457) and Retaining Plate (VW 309). Fig. 26: Removing Engine Mount Nuts & Subframe Bolts 13. Prior to installing transaxle, clean ATF cooler and ATF lines before installation. See SERVICING - A/T article. Ensure that the dowel sleeves are correctly located. The threaded holes in the flange shaft behind the transaxle must be cleaned of all locking material residue. A thread tap is suitable to perform this procedure. Ensure that torque converter seats correctly in transaxle января 2005 г. 0:01:51 Page Mitchell Repair Information Company, LLC.

30 CAUTION: If the torque converter is in incorrect installation position, the follower of the converter or ATF pump will be destroyed when the transaxle is connected to the engine. Push on torque converter hub to first stop at oil seal. Turn torque converter inward using light pressure until opening in hub engages with follower of pump sprocket and until torque converter can be felt to slip in place. Using depth gauge, measure converter installed distance. If the converter is correctly positioned, the distance between the contact surfaces below at the tapped holes in the converter and the contact surface of the converter housing of transaxle will be about.91" (23 mm). See Fig. 44. If the converter is not correctly positioned, the distance is about.43" (11 mm). 15. Set up Transaxle Support (3282). Transaxle Support (3282) is set up with Adjusting Plate (3282/19) for transaxle installation. The symbols on the adjusting plate indicate the mounts required, the arrow points forward. See Fig. 8. Place transaxle on transaxle jack. Secure transaxle to Transaxle Support (3282) with bolt (A). See Fig Place transaxle jack under vehicle. Guide transaxle in between lowered subframe and underbody. Align transaxle to engine. Screw engine/transaxle connecting bolt hand tight in each side. 17. Bolt torque converter and drive plate together. See Fig. 24. Screw in nuts by hand and then tighten to specification. See TORQUE SPECIFICATIONS. Install upper engine/transaxle securing bolts and tighten to specification. See TRANSAXLE-TO-ENGINE BOLT TORQUE SPECIFICATIONS (2.8L) table. For bolt locations, see Fig Lift engine/transaxle assembly 8 turns on the spindle. To do this, raise engine/transaxle assembly in stages, alternating on each spindle 2 turns at a time. See Fig. 17. At the same time, raise engine/transaxle assembly on Transaxle Jack (VAG 1383 A), with aid of an assistant. 19. NOTE: For subframe installation with wheel alignment, perform the following procedure If holes (1) and (2) did not align before loosening subframe, the vehicle must be aligned. See Fig. 11. Install subframe using bolts originally removed. These bolts must be replaced following wheel alignment. When doing this, tighten original bolts to specification. See TORQUE SPECIFICATIONS. NOTE: For subframe installation without wheel alignment, perform the following procedure. If holes (1) and (2) did align before loosening subframe, the vehicle does not need alignment. See Fig. 11. Install subframe with NEW bolts. Observe tightening sequence. Install left and right hand engine mount nuts (1). Install bolts (2) for transaxle mounting to subframe. See Fig. 26. NOTE: Transaxle mounting bolts (2) in previous step, are identified as bolts (A) in the following step. When tightening bolts (A) to transaxle mounting (E), positions (B) and (C) should be ignored on hydraulic transaxle mountings (D) and (H) as bolts (F) and (G) are screwed directly in the transaxle mounting. See Fig. 27. Tighten bolts to specification. See TORQUE SPECIFICATIONS. 4 января 2005 г. 0:01:51 Page Mitchell Repair Information Company, LLC.

31 Fig. 27: Tightening Transaxle Mounting Bolts 22. Once subframe is bolted to body and engine/transaxle assembly is bolted to subframe, remove bolt (A). See Fig. 9. Remove Transaxle Jack (VAG 1383 A). Apply anti-corrosion agent to point of contact between bolt (A) and oil pan. 23. Install side and lower connecting bolts for engine to transaxle and tighten to specification. See TRANSAXLE-TO-ENGINE BOLT TORQUE SPECIFICATIONS (2.8L) table. For bolt locations, see Fig Shift selector shaft lever into "2" position and carefully press ball head of selector lever cable (1) into selector shaft lever (2) using a pair of pliers. See Fig. 28. The selector shaft lever (2) must not be bent when doing this, otherwise the selector mechanism will not be able to be adjusted correctly. Push selector lever cable (1) forward fully (arrow) to shift selector lever shaft (2) into "2" position. 25. Bolt support bracket of selector lever cable to transaxle (arrows). See Fig. 4. Install starter. On 4WD 4 января 2005 г. 0:01:51 Page Mitchell Repair Information Company, LLC.

32 vehicles, install cover plate (B) and bolts (arrows). Fit heat shield (A) to vehicle undercover. See Fig. 25. On all models, install ATF lines (1) to engine/transaxle assembly. See Fig. 23. Tighten union nut to 22 ft. lbs. (30 N.m). Remove ATF line holder (arrow) from engine oil pan. 26. Connect connector to multifunction TR switch (2). Connect connector for transaxle wiring harness and secure with locking lever (3). Install noise insulation tray holder (1). Replace cable tie (4). See Fig. 20. Reconnect speedometer sender connector (arrow A). Screw engine speed (RPM) sensor (arrow B) into transaxle. See Fig Install drive axles (1) to flanged shafts. Install protective plate and bolts (arrows) for left and right hand drive axles. See Fig. 19. The third bolt cannot be seen in the illustration. Install front exhaust system with catalytic converter. Install noise insulation tray (arrows). See Fig. 18. Install front wheels. Remove Support Bar Assembly ( A). See Fig. 17. Install intake hose to intake manifold. 28. Install engine cover and tighten bolts (arrows). See Fig. 16. Reconnect negative battery cable. Check selector lever cable adjustment, and adjust if necessary. With transaxle installed, check final drive oil level. Check and top off ATF level. See SERVICING - A/T article. When checking ATF level, check ATF line connections (A) and (B) for leaks. See Fig. 29. TRANSAXLE-TO-ENGINE BOLT TORQUE SPECIFICATIONS (2.8L) Bolt No. Bolt Size Ft. Lbs. (N.m) 01V (V6) (1) 1 M 12 X (65) 2 M 12 X (65) 3 M 12 X (65) 4 M 10 X (45) 5 M 10 X (45) 6 M 10 X (65) 7 (With Bracket) M 12 X (65) (1) For bolt locations, see Fig января 2005 г. 0:01:51 Page Mitchell Repair Information Company, LLC.

33 Fig. 28: Positioning Selector Lever Cable & Shaft Lever 4 января 2005 г. 0:01:51 Page Mitchell Repair Information Company, LLC.

34 Fig. 29: Checking ATF Lines At Transaxle 4 января 2005 г. 0:01:52 Page Mitchell Repair Information Company, LLC.

35 Fig. 30: Transaxle-To-Engine Bolt Identification (Passat V6) 4.0L Removal & Installation NOTE: In the following procedures, letters and numbers in parenthesis are shown in illustrations. 4 января 2005 г. 0:01:52 Page Mitchell Repair Information Company, LLC.

36 NOTE: CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. Radio/cassette or radio/cd player is equipped with an anti-theft protection circuit. Whenever battery is disconnected, radio will go into anti-theft mode. When battery is reconnected, radio will display CODE, and will be inoperative until proper code number is entered. Obtain security code before disconnecting battery. 1. Turn ignition off and disconnect negative battery cable. Remove intake air duct, upper part of air filter and intake hose. Drain coolant. Unclip connectors (arrows) from holder. See Fig. 31. Unclip connector (arrow) for air conditioning compressor from holder. See Fig Disconnect oil filler neck from engine. Install Pull Out Device ( A) with Frame ( A/1) and Adapter ( A/18). Long edge of Adapter ( A/18) faces forward. Attach third Spindle ( A/10) with extra Hook ( A/2) to suspension eyelet on left rear of engine. Attach a second Hook ( A/2) to eyelet on right rear of engine. See Fig. 33. Release engine/transaxle assembly tension slightly using spindles. 3. Loosen wheel bolts. Raise and support vehicle. Remove front wheels. Remove front right wheel arch liner. Remove front exhaust pipes. 4. Remove right and left drive axle protective plate and bolts (arrows). Third screw is not visible in illustration. Unbolt drive axles (1) from flanges on left and right and secure to the side. See Fig. 19. Remove heat shield (A) from floor of vehicle. Remove cover plate (B) and bolts (arrows). See Fig. 25. Mark drive shaft position at transaxle for reassembly reference. Separate drive shaft from transaxle. Pull drive shaft back to stop and secure out of the way. Remove selector lever cable deflector. 5. To facilitate installation, mark position of mounting for selector lever cable to transaxle, and remove bolts (arrows). See Fig. 4. Disconnect selector lever cable from lever/third motion shaft (arrow). See Fig. 6. Disassemble holder for sound insulator (1). Disconnect wiring connector (2) for multifunction TR switch. Move locking lever (3) aside, and disconnect connector for transaxle wiring harness. Cut cable tie (4). See Fig января 2005 г. 0:01:52 Page Mitchell Repair Information Company, LLC.

37 Fig. 31: Removing Connectors From Holder 4 января 2005 г. 0:01:52 Page Mitchell Repair Information Company, LLC.

38 Fig. 32: Removing Connector For AC Compressor From Holder 4 января 2005 г. 0:01:52 Page Mitchell Repair Information Company, LLC.

39 Fig. 33: Installing Support Assembly 4 января 2005 г. 0:01:52 Page Mitchell Repair Information Company, LLC.

40 6. Disconnect connector from speedometer sensor (arrow). See Fig. 34. Remove engine speed sensor from lower mounting (arrow). See Fig. 35. Remove bolt (1) holding ATF lines (2) from engine. See Fig Place drain plug underneath ATF lines. Thoroughly clean area where ATF line/transaxle connect. Remove ATF lines from engine/transaxle assembly (arrow) and secure out of the way. See Fig. 37. Plug ATF lines and transaxle with clean stoppers. Remove bolts (arrows) and remove stop for torque support (1). See Fig Place drain pan underneath coolant pipe holder. Remove hex nut (1) for coolant pipe holder (2) from engine oil pan. Remove coolant pipe as shown in illustration. Remove hex nut (3) for oil tube (4). Pull oil tube out of oil pan and plug oil pan and tube with clean stoppers. Remove bolt (5) for wiring harness from right engine mount. See Fig Remove bolt (arrow) for air conditioning ducting from engine oil pan. See Fig. 40. Unclip retaining bracket for coupling rod (1) of left front level control system sensor from front left support guide (2). See Fig. 41. Install Transaxle Mounting (3282). Transaxle Mounting (3282) for transaxle is installed with the Adjustment Plate (3282/19). The symbols on the adjustment plate show the mountings required, and the arrow points in the direction of travel. See Fig января 2005 г. 0:01:52 Page Mitchell Repair Information Company, LLC.

41 Fig. 34: Disconnecting Speedometer Sensor Connector 4 января 2005 г. 0:01:52 Page Mitchell Repair Information Company, LLC.

42 Fig. 35: Removing Engine Speed Sensor From Lower Mount 4 января 2005 г. 0:01:52 Page Mitchell Repair Information Company, LLC.

43 Fig. 36: Removing ATF Line Bolt 4 января 2005 г. 0:01:52 Page Mitchell Repair Information Company, LLC.

44 Fig. 37: Removing ATF Lines From Engine/Transaxle Assembly 4 января 2005 г. 0:01:52 Page Mitchell Repair Information Company, LLC.

45 Fig. 38: Removing Torque Support Stop 4 января 2005 г. 0:01:52 Page Mitchell Repair Information Company, LLC.

46 Fig. 39: Removing Bolt, Nuts & Coolant Pipe 4 января 2005 г. 0:01:52 Page Mitchell Repair Information Company, LLC.

47 Fig. 40: Removing AC Ducting Bolt From Engine Oil Pan 4 января 2005 г. 0:01:52 Page Mitchell Repair Information Company, LLC.

48 Fig. 41: Removing Retaining Bracket For Coupling Rod 10. Position Transaxle Jack (VAG 1383 A) and Transaxle Mounting (3282) under transaxle, align adjustment plate parallel to transaxle and support transaxle on it. Fasten transaxle to Transaxle Mounting (3282) using bolt (A). See Fig. 9. Pack space between transaxle mounting and oil pan with washers. 11. Remove nuts (1) on lower left and right of engine bracket. Remove bolts (2) on transaxle mount/support. Disconnect lines from the engine mountings, unclip cables from assembly support and secure to one side. See Fig NOTE: If holes are not aligned in the following step, check wheel alignment measurements after tightening subframe. Subframe may also be referred to as assembly support. Before loosening the subframe, it is essential to check whether at least holes (1) and (2) are aligned on both sides of the vehicle using Mandrel (3393). See Fig. 11. Hole (3) has no relevance at this time. 4 января 2005 г. 0:01:53 Page Mitchell Repair Information Company, LLC.

49 Remove bolts (1) and (2) at rear of subframe on both sides of vehicle. Remove bolts (3) at front of subframe on both sides of vehicle. Remove bolts (4) (2 on each side of vehicle). See Fig Remove hex nut (2) for ground cable (1) from right engine bracket (3). Loosen bolts (arrows) on right motor bracket and remove bracket. See Fig. 42. Disconnect electrical connections from alternator and remove wiring harness from alternator. Remove starter. Disconnect torque converter from drive plate (3 nuts). See Fig. 24. Turn crankshaft 1/3 of a turn to access each nut. 14. Using quick release catch, disconnect coolant hose (arrow) under left side rail from coolant pipe (not visible in illustration). See Fig. 43. Ensure no components are damaged as the transaxle is lowered. Climb up ladder in order to lower engine/transaxle assembly with spindles. 15. Lower engine/transaxle assembly about 4 turns using spindles. Lower assembly using spindles, lowering it alternately 2 turns. See Fig. 33. At same time, lower engine/transaxle assembly using Transaxle Jack (VAG 1383 A) with the aid of an assistant. Unclip wiring for oxygen sensors on transaxle. 16. Remove engine/transaxle connecting bolts. While pushing transaxle away from engine, press torque converter out of drive plate. Press torque converter against ATF pump (arrow). See Fig. 13. Carefully retract transaxle, and lower it. Secure torque converter to prevent it from falling out. When working on the transaxle, torque converter must be secured to the repair stand with Transport Device (3457) and Retaining Plate (VW 309). Fig. 42: Removing Bolts, Hex Nut & Bracket 4 января 2005 г. 0:01:53 Page Mitchell Repair Information Company, LLC.

50 Fig. 43: Disconnecting Coolant Hose Under Left Side Rail 17. Prior to installing transaxle, clean ATF cooler, secondary ATF cooler and ATF lines. See SERVICING - A/T article. Ensure dowel sleeves are seated correctly. Clean any adhesive residue from tapped holes in rear flanged shaft of transaxle. This can be done using a tap thread. Before installing transaxle, ensure torque converter has been correctly inserted in transaxle. 18. CAUTION: If the torque converter is in incorrect installation position, the follower of the converter or ATF pump will be destroyed when the transaxle is connected to the engine. Push on torque converter hub to first stop at oil seal. Turn torque converter inward using light pressure until opening in hub engages with follower of pump sprocket and until torque converter can be felt to slip in place. Using depth gauge, measure converter installed distance. If the converter is correctly positioned, the distance between the contact surfaces below at the tapped holes in the converter and 4 января 2005 г. 0:01:53 Page Mitchell Repair Information Company, LLC.

51 the contact surface of the converter housing of transaxle is about.91" (23 mm). See Fig. 44. If the converter is not correctly positioned, the distance is about.43" (11 mm). Fig. 44: Measuring Torque Converter Installed Distance 19. Install Transaxle Mounting (3282). Transaxle Mounting (3282) for transaxle is installed with the Adjustment Plate (3282/19). The symbols on the adjustment plate show the mountings required, and the arrow points in the direction of travel. See Fig. 8. Place transaxle on transaxle jack. 20. Fasten transaxle to Transaxle Mounting (3282) using bolt (A). See Fig. 9. Position transaxle jack underneath vehicle. Position transaxle between lowered assembly support and vehicle floor. Alternately lift and push transaxle forward toward engine. Align transaxle with engine. Insert a bolt on each side of engine/transaxle assembly and tighten finger tight. 21. Bolt converter and drive plate together. See Fig. 24. Insert nuts by hand and tighten to specification. 4 января 2005 г. 0:01:53 Page Mitchell Repair Information Company, LLC.

52 See TORQUE SPECIFICATIONS. Tighten engine/transaxle bolt (1). Insert engine/transaxle bolt (2) and bolt for wiring harness (3) and thread in finger tight. Place open side of holder for wiring harness (3) onto hex bolt head (1). Tighten bolt (2) to specification. See Fig Insert remaining engine/transaxle bolts and tighten to specification. See TRANSAXLE-TO- ENGINE BOLT TORQUE SPECIFICATIONS (4.0L) table. For bolt locations, see Fig. 46. A holder or ground connection is also screwed onto some of the bolts. Clip harnesses for oxygen sensor onto transaxle. TRANSAXLE-TO-ENGINE BOLT TORQUE SPECIFICATIONS (4.0L) Bolt No. Bolt Size Ft. Lbs. (N.m) 01V (V8) 1 (1)(2) M 12 X (65) 2 M 12 X (65) 3 (3) M 12 X (65) 4 M 10 X (45) 5 (With Disc) M 10 X (65) (1) For bolt locations, see Fig. 46. (2) Item "A" is dowel sleeve locations. (3) With holder for wiring harness 4 января 2005 г. 0:01:53 Page Mitchell Repair Information Company, LLC.

53 Fig. 45: Installing Wiring Harness Holder 4 января 2005 г. 0:01:53 Page Mitchell Repair Information Company, LLC.

54 Fig. 46: Transaxle-To-Engine Bolt Identification (Passat V8) 23. Climb up ladder in order to lift engine/transaxle assembly with spindles. Lift engine/transaxle assembly about 4 turns using spindles. Lift assembly using spindles, raising it alternately 2 turns. See Fig. 33. At the same time, raise engine/transaxle assembly using Transaxle Jack (VAG 1383 A) with aid of an assistant. 24. Using quick release catch, connect coolant hose (arrow) under left side rail to coolant pipe (not visible in illustration). See Fig. 43. Install starter. Connect electrical connections to alternator and fasten wiring harness to alternator. 25. Install right engine bracket (3) and tighten bolts (arrows). Attach ground cable (1) to right engine bracket using hex nut (2). See Fig NOTE: For assembly support installation with wheel alignment, perform the 4 января 2005 г. 0:01:53 Page Mitchell Repair Information Company, LLC.

55 following procedure. 27. If holes (1) and (2) did not align before loosening assembly support, the vehicle must be aligned. See Fig. 11. Install assembly support using bolts originally removed. These bolts must be replaced following wheel alignment. When doing this, tighten original bolts only to specification. See TORQUE SPECIFICATIONS. NOTE: For assembly support installation without wheel alignment, perform the following procedure. If holes (1) and (2) did align before loosening assembly support, the vehicle does not need alignment. See Fig. 11. Install assembly support with NEW bolts. Observe tightening sequence. Install left and right hand engine mount nuts (1). Install bolts (2) for transaxle mounting to assembly support and tighten to specification. See Fig Remove bolt (A) when assembly support has been bolted to body and engine/transaxle assembly has been bolted to assembly support. Remove Transaxle Jack (VAG 1338 A). Apply an anti-corrosion agent at the point where bolt (A) touches the oil pan. See Fig. 9. Clip lines for engine mounted onto assembly support and attach lines to engine mount. 29. Install bolt (arrow) for air conditioning ducting to engine oil pan. See Fig. 40. Attach retaining bracket for coupling rod to left front level control system sensor from front left support guide. 30. Install bolt (5) for wiring harness onto right engine mount. Insert oil tube (4) into oil pan and tighten hex nut (3). Install coolant pipe (2) and tighten hex nut (1) for coolant pipe bracket on engine oil pan. See Fig Attach stop for torque support (1) and tighten bolts (arrows) to specification. See Fig. 38. Moisten NEW "O" rings with ATF. Ensure that "O" rings are seated correctly so they do not slip out of position when ATF lines are inserted. Insert ATF lines by hand into transaxle until they can go no further. Do not tighten screw (2) until the ATF lines have been fully inserted. See Fig Screw ATF line holder (2) to engine. See Fig. 36. Install engine speed sensor to lower mounting (arrow). See Fig. 35. Attach connector to speedometer sensor (arrow). See Fig. 34. Attach multifunction TR switch connector (2). Attach connector for transaxle wiring harness and secure using locking lever (3). Attach bracket for sound insulation (1). Replace cable tie (4). See Fig Move lever/third motion shaft to "2" position and carefully press ball end of selector lever cable (1) onto lever of third motion shaft. See Fig. 28. Ensure the lever of the third motion shaft (2) is not bent during this operation as it will otherwise not be possible to adjust the gearshift exactly. 34. Install selector lever cable block tight according to marking on transaxle (arrows). See Fig. 4. Attach deflector/selector lever cable. Attach cover plate (B) and bolts (arrows). Attach heat shield (A) to floor of vehicle. See Fig. 25. Attach drive axles (1) to flanged shafts. See Fig. 19. Remove right and left drive axle protective plate and bolts (arrows). Third screw is not visible in illustration. 35. Install front exhaust pipes. Install right front wheel arch liner. Install front wheels. Remove Pull Out Device ( A). Attach oil filler neck to engine. Clip connector (arrow) for air conditioning compressor into holder. See Fig. 32. Clip connectors (arrows) into holder. See Fig Install intake air duct, upper part of air filter and intake hose. Connect negative battery cable. Check selector lever cable and adjust if necessary. Check transaxle oil in final drive. Check ATF level and top off. Check connections (A) and (B) of ATF lines for leaks while checking ATF level. See Fig. 29. See SERVICING - A/T article. 37. Fill engine with 50/50 solution of water and coolant. Tighten radiator drain plug to specification. Start engine and maintain an engine speed of about 2000 RPM for about 3 minutes. Allow engine to run at idling speed until lower hose on radiator becomes hot. Turn ignition switch off. Check coolant level 4 января 2005 г. 0:01:53 Page Mitchell Repair Information Company, LLC.

56 and top up as necessary: When engine is at normal operating temperature, coolant level must be on MAX mark. When engine is cold, coolant level can be between MIN and MAX. marks. TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) ATF Line-To-Transaxle Bolt (1.8L) 15 (20) ATF Line Union Nut 22 (30) Axle Shaft-To-Wheel Hub (1) M 14 Bolt 85 (115) M 16 Bolt 140 (190) Drive Axle-To-Transaxle Bolt (FWD) 59 (80) Drive Axle-To-Transaxle Bolt (4WD & AWD) M 8 Bolt 30 (40) M 10 Bolt 57 (77) Drive Shaft Bolt (4WD & AWD) 41 (55) Exhaust Pipe Bolt (4.0L) 22 (30) Exhaust Pipe Nut 1.8L 22 (30) 2.8L 18 (25) Heat Shield Bolt 18 (25) Intermediate Bearing Nut (4WD & AWD) 18 (25) Left & Right Rear Transaxle Mount Bolts (2) "A" 17 (23) "B" 30 (40) "C" 30 (40) "D" 7 (10) Radiator Drain Plug 15 (20) Selector Lever Cable Support Bracket Bolt 17 (23) Starter Bolt 1.8L & 2.8L 48 (65) 4.0L 37 (50) Starter Bracket Nut 16 (22) Subframe (Support Assembly)-To-Body (3) M 8 Bolt 17 (23) M 10 Bolt 44 (60) M 12 Bolt (4) 81 (110) Torque Converter-To-Drive Plate Nut 63 (85) Transaxle Mounting Bolts (2.8L) (5) Bolt "A" 17 (23) Bolt "B" With "F" 37 (50) 4 января 2005 г. 0:01:53 Page Mitchell Repair Information Company, LLC.

57 Bolt "G" 37 (50) Wheel Bolt 89 (120) INCH Lbs. (N.m) ATF Bracket Bolt (1.8L & 2.8L) 89 (10) ATF Line Bracket Bolt (1.8L & 2.8L) 89 (10) Electrical Connection At Starter (4.0L) 115 (13) Selector Lever Cable-To-Support Bracket Bolt 106 (12) Starter Connector Eyelet Nut (1.8L & 2.8L) 115 (13) Starter Nut (1.8L) 35 (4) (1) Tighten to specification plus an additional 180 degrees. Always replace bolts. (2) For bolt locations, see Fig. 12. (3) Always replace bolts. (4) Tighten to specification plus an additional 90 degrees. (5) For bolt locations, see Fig января 2005 г. 0:01:53 Page Mitchell Repair Information Company, LLC.

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