1990-97 Passat Models
If equipped with electronically theft-protected radio, obtain the security code before disconnecting the battery.
- Disconnect the negative battery cable.
- Disconnect the backup light switch connector and the speedometer cable from the transaxle, plug the speedometer cable hole.
- Remove the clutch slave cylinder without disconnecting the hydraulic line. Support the cylinder from the body with wire.
- On the cable shift linkage, remove the backup light switch bracket. Disconnect the cable from the relay lever but remove the gearshift lever with the cable still attached. Remove the cable support and set the cables aside.
- If necessary, remove the intake hose from the air flow sensor.
- Connect the engine sling Tool No. VW-10-222A, or equivalent, to the loop in the cylinder head and just take the weight of the engine off the mounts.
On the 2.0L 9A 16V engine, the idle stabilizer valve must be removed to attach the tool. Do NOT try to support the engine from below.
- Remove the upper transaxle-to-engine bolts.
- Raise and safely support the vehicle and remove the front wheels.
- Remove the drain plug and drain the oil from the transaxle into a suitable container.
- Remove the starter and front mount.
- Remove the 3 bolts from the right side mount, between the engine and the firewall.
- Remove the large center bolt from the left side transaxle mount. On vehicles with ABS, this bolt can be reached by removing the cooling system overflow bottle.
- Remove the radiator fan shroud and fan as an assembly.
- Remove the long transaxle support bracket that connects the front and rear mounts on the left side.
- Remove the heat shield for the right side inner CV joint.
- Disconnect the halfshafts from the output flanges and support them from the body.
- Remove the left rear transaxle mount. It may be necessary to push the engine/transaxle rearward to get the lower bolt out.
- Lower the transaxle slightly.
- Remove the bell housing cover and position a jack under the transaxle.
- Remove the last transaxle-to-engine bolts and gently pry the transaxle away from the engine. Lower it carefully from the vehicle.
- Press the clutch release lever towards the transaxle housing and secure it with a pin or 8mm bolt.
- Coat the input shaft lightly with molybdenum grease and carefully fit the transaxle in place. If necessary, put the transaxle in any gear and turn an output flange to align the input shaft spline with the clutch spline.
- Install the engine-to-transaxle bolts and torque to 59 ft. lbs. (80 Nm).
- When installing the mounts to the transaxle, torque the left and rear bracket-to-transaxle bolts to:
- Bracket-to-transaxle bolts: 18 ft. lbs. (25 Nm)
- Torque the end mount-to-transaxle bolts to:
- End mount-to-transaxle bolts: 44 ft. lbs. (60 Nm).
Don't forget the balance weight.
- Install, but Do NOT torque, the bolts that go into the rubber mounts.
- Install the starter and front mount.
- With all mounts installed and the transaxle safely in the vehicle, allow some slack in the lifting equipment. With the vehicle safely supported, shake the engine/transaxle as a unit to settle it in the mounts. Torque all mounting bolts, starting at the rear and working forward. Torque the bolts that go into the rubber transaxle mounts to:
- Rubber transaxle mounts: 44 ft. lbs. (60 Nm).
- Install the halfshafts and torque the bolts to:
- Halfshafts bolts: 33 ft. lbs. (45 Nm).
- Install the heat shield.
- Remove the pin or bolt from the release lever and install the clutch slave cylinder and torque the bolts to:
- Clutch slave cylinder bolts: 18 ft. lbs. (25 Nm).
- Lubricate the shift linkage lightly with molybdenum grease and install it. Torque the bolts to:
- Shift linkage bolts: 18 ft. lbs. (25 Nm)
- Adjust the linkage as required.
- Install the radiator fan assembly and connect the wiring.
- The balance of assembly is in reverse order of removal making sure to refill the transaxle with the proper lubricant.
- Not the radio security code and disconnect the negative battery cable.
- On 1.8L engines;
- disconnect the electrical connectors for the wastegate solenoid valve, the Evaporative Emission (EVAP) canister purge regulator valve, the power output stage and the Mass Airflow (MAF) sensor at the right front of the engine compartment above the air filter housing.
- Disconnect the hoses attached to the air filer housing and remove the housing.
- Remove the coolant reservoir tank and set aside.
- Disconnect the Heated Oxygen (HO 2 S) Sensor and free the wire.
- Remove the nuts securing the turbocharger to the front exhaust pipe.
- On V6 engines;
- Remove the air intake duct.
- Unbolt the coolant reservoir fasteners and set aside.
- Remove both Heated Oxygen (HO 2 S) Sensors.
- Remove all transmission-to-engine mounting fasteners that are accessible from the top of the engine.
- Raise and safely support the vehicle.
- Remove the lower engine shield and mounting bracket.
- On 1.8L engines;
- Remove the right halfshaft heat shield.
- Disconnect the right side transmission support and mount.
- Loosen the exhaust clamping sleeve and slide it toward the catalytic converter.
- Remove the catalytic converter along with the exhaust pipe.
- On V6 engines;
- Remove both halfshaft heat shields.
- Remove the left and right exhaust down pipes along with the catalytic converter.
- Remove the Crankshaft Position (CKP) sensor from the left side of the transmission.
- Remove the drive axles from the transmission output flanges.
- Disconnect the Vehicle Speed (VSS) Sensor.
- Disconnect the multi-function sensor.
- Disconnect the remaining electrical connectors and ground cables from the transmission-to-engine mounting bolts.
- Remove the starter assembly and support it, leaving the wires connected.
- Disconnect the shift rod and support rods from the transmission.
- On four wheel drive models;
- Remove the heat shield for the driveshaft near the center differential.
- Matchmark and remove the driveshaft. Rest it on the heat shield, and tie it off onto the fuel line support bracket using mechanic's wire.
- Remove all the remaining transmission-to-engine mounting bolts EXCEPT the bottom two bolts.
- Support the transmission with a suitable jack, such as Tool No. VAG 1383A and fixture Too No. 3282.
- On 1.8L engines, remove the left transmission support from the mount.
- On V6 engines, remove the left and right transmission support brackets complete with their mounts from the transmission and subframe.
- Remove the remaining transmission-to-engine mounting bolts and carefully press the transmission off the dowel sleeves.
- Once the input shaft is clear of the clutch, carefully lower the transmission enough to access the clutch slave cylinder and remove the cylinder leaving the line attached. Secure the slave cylinder to the side.
- Lower the transmission making sure the halfshafts are clear while lowering the transmission.
- Installation is in reverse order of removal noting the following.
- Clean the slave cylinder and shift rod lever mounting holes of residual locking compound using a suitable tap.
- Clean the transmission input shaft splines and apply a light coating of Part No. G 000 100, or an equivalent, to the splines. Do NOT grease the guide sleeve (tube).
- Coat the slave cylinder pivot rod with a light coating of copper grease, such as Part No. 381 351 TE.
- Make sure the dowel sleeves are properly installed.
- Replace all self-locking nuts.
- Observe the following component torque specifications:
- Slave cylinder mounting bolts: 18 ft. lbs. (25 Nm)
Engine-to-transaxle mounting bolts:
M12 bolts: 48 ft. lbs. (65 Nm)M10 bolts: 33 ft. lbs. (45 Nm)M8 bolts: 18 ft. lbs. (25 Nm).
M8 bolts: 33 ft. lbs. (45 Nm)M10 bolts: 59 ft. lbs. (80 Nm).Transaxle mount bolts: 30 ft. lbs. (40 Nm).Shift rod bolt: 15 ft. lbs. (20 Nm).
- Lift the transmission upward until the slave cylinder can be installed and install the slave cylinder.
- If equipped, install the intermediate plate properly between the engine and transmission.
- Install the lower transmission-to-engine mounting bolts and then the starter motor.
- On four wheel drive vehicles;
- Clean the transmission rear output flange bolt holes using a tap.
- Install the driveshaft using a new gasket.
- Install the shift rod and pivot rod, then check the shift rod adjustment and adjust as necessary.
- Install and align the exhaust system making sure it is free of binding or being stressed.
- Check and top off the transmission oil level as necessary.
- Connect the negative battery cable then reset the following electrical components;
- Enter the anti-theft code for the radio.
- Operate each window fully closed, fully open and fully closed again and hold the window switch in the closed position for at least one full second to activate the one-touch function.
- Set the clock to the correct time.