Removing gearbox, Golf Sportsvan, Touran, with petrol engine — VW

🧭 Before you start

Fits: VW Golf Sportsvan (AM1, 2014–2020), VW Touran II (5T, 2015–)

• Special tools named: T40093/3, T10346/1

Don't miss

• Then, mark adapter T40093/3-6 with T40093/3-6A.
• Remove clutch slave cylinder (arrows B), lay to side and secure with wire. Do not open pipe/hose system.
• If present, pull off wires in front area of web on both longitudinal members (arrow). Do not disconnect pipe/hose system.
• Risk of damage to decoupling element.Observe 26Emission control; Assembly overview – emission control. — Remove front exhaust pipe with catalytic converter from engine 26Emission control; Assembly overview - emission control.
• Remove electrical wiring (A) from bracket (B); do not open system (wires may differ from those shown in diagram).

📋 Procedure

1. If necessary, cut off the marked area.
2. Round off the front edges.
3. Protect adapter against corrosion.
4. Then, mark adapter T40093/3-6 with T40093/3-6A.
5. Disconnect battery Electrical system27Battery; Disconnecting and connecting battery.

6. If fitted, remove engine cover panel 10Engine cover panel; Removing and installing engine cover panel.
7. Remove complete air filter housing 24Air filter; Removing and installing air filter housing.
8. Remove battery tray Electrical system27Battery; Removing and installing battery tray.
9. Pull off clip (arrow 1), and remove gate relay lever together with cable end-piece .
10. Remove securing clip (arrow 2) for gear selector cable from gearbox selector lever (A).
11. Pull gear selector cable off pin.
12. Remove gearbox selector lever (A) by removing nut (arrow 3).
13. Remove cable support bracket from gearbox (arrows).
14. Then tie up gear selector cable and gate selector cable.
15. If installed, remove bracket (B) from gearbox. Pull retainer off pipe/hose assembly (A).
16. Then remove gearbox support (arrow A).
17. Remove clutch slave cylinder (arrows B), lay to side and secure with wire. Do not open pipe/hose system.
18. ⚠ Risk of damage to clutch slave cylinder.Do not press the clutch pedal if the clutch slave cylinder has been removed from the gearbox with the pipe/hose assembly still attached. — Disconnect earth strap at upper engine/gearbox connecting bolt or at upper starter bolt.
19. Pull connector (arrow 1) off reversing light switch F4.
20. Now remove connector (arrow 2) and wire (arrow 3) from starter.
21. Then remove upper securing bolt on starter.
22. Remove upper engine/gearbox connecting bolts.
23. If there are hose and cable connections in area of engine support eye for support bracket10 - 222 A, remove these now.
24. Install support bracket10-222 A as follows:
25. On both sides of vehicle, insert adapters10 - 222 A /29 between upper wheel housing longitudinal member and mounting plate for wing located underneath.
26. Push adapter10 - 222 A /18 and two connecting pieces T40091/3 onto support bracket10-222 A.
27. Secure support bracket10-222 A to adapters10 - 222 A /29.
28. If present, pull off wires in front area of web on both longitudinal members (arrow). Do not disconnect pipe/hose system.
29. Place adapters T40093/3-6A onto both longitudinal members (the illustration shows the left longitudinal member).
30. If necessary, carefully unclip any pipes for air conditioning system in front area. Do not disconnect pipe/hose system Heating, air conditioning87Refrigerant circuit; System overview - refrigerant circuit.
31. Position adapter T40093/3-6A onto left longitudinal member right behind filler pipe for washer fluid reservoir (B).
32. Then, hook spindles into lifting eye of engine. Use shackles10 - 222 A /12, if necessary.
33. Take up weight of engine/gearbox assembly and support bracket on spindles.
34. With vehicle standing on its wheels, loosen front left flange bolt (arrow) 90° at most, or wheel bearing will be damaged Running gear, axles, steering40Drive shaft; Removing and installing drive shaft.
35. Install support bracket10-222 A as follows:
36. Contrary to way shown in one from next diagram (fig. 2), push spindles onto support bracket10-222 A.
37. Push adapter10-222A/16 onto support bracket10-222 A.
38. Secure support bracket10-222 A to adapters10 - 222 A /29.
39. Place support bracket10-222 A with adapters10 - 222 A /29 on carrier directly behind mounting plate (arrow).
40. Screw on and tighten bracket T10346 or T10346/1 to rear left mounting hole for battery tray.
41. To do this, use a collar bolt M6 x 80 or a securing bolt for battery tray.
42. Join bar2024 A / 1 from lifting tackle2024 A at top with shackle10 - 222 A /12 on adapter10-222A/16 and secure at bottom of bracket T10346/1 with split pin (arrow).
43. Then insert spindles in both mounting holes of engine via shackles10 - 222 A /12 (previous diagram shows just one spindle).
44. Take up weight of engine/gearbox assembly and support bracket on spindles.
45. Remove lower part of front left wheel housing liner General body repairs, exterior66Wheel housing liner; Assembly overview - front wheel housing liner.
46. Remove noise insulation General body repairs, exterior66Noise insulation; Assembly overview - noise insulation.
47. Gearboxes for vehicles with start-stop system: pull connector (arrow) from gearbox neutral position sender G701.
48. Remove all lines from gearbox.
49. Remove nut (arrow) and remove retainer for electrical lines.
50. Remove starter Electrical system27Starter; Assembly overview - starter.
51. Unscrew nut (1) from coupling rod (3) on both sides.
52. Withdraw coupling rod (3) from anti-roll bar (2) on both sides.
53. If fitted, unbolt front vehicle level sender G78 from transverse link Running gear, axles, steering43Vehicle level sender; Assembly overview - front vehicle level sender.
54. Remove left drive shaft Running gear, axles, steering40Drive shaft; Removing and installing drive shaft.
55. Remove left drive shaft from gearbox and tie it up. Do not damage surface protection Running gear, axles, steering40Drive shaft; Removing and installing drive shaft.
56. If fitted, remove drive shaft heat shield (arrows)Running gear, axles, steering40Drive shaft; Removing and installing drive shaft heat shield.
57. Remove right drive shaft from gearbox and tie it up. Do not damage surface protection Running gear, axles, steering40Drive shaft; Removing and installing drive shaft.
58. ⚠ Risk of damage to decoupling element.Observe 26Emission control; Assembly overview – emission control. — Remove front exhaust pipe with catalytic converter from engine 26Emission control; Assembly overview - emission control.
59. Remove pendulum support.
60. Remove vacuum hose for brake system from plenum chamber bulkhead and engine; do not open system Brake system47Brake servo/brake master cylinder.

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