Run this check for max. If the check requires more time, allow for a short break every 10 seconds. Checking the power steering fluid level Screw off supply tank cover. The supply tank is fitted to the right-hand wheel house wall inside the engine compart- ment. Run engine at idle. Wipe off dipstick, screw cover back on and remove again. The fluid level must be between both marks.
To bleed the complete system after new steering components or lines have been fitted or after excessive hydraulic fluid los- ses have been remedied, start engine several times and turn off immediately as soon as it has started. This process causes the fluid level in the supply tank to drop rapidly. The supply tank must never run empty. As soon as the fluid level no longer drops when the engine is started for a short mo- ment, start the engine again and let it run at idle speed.
Turn steering wheel rapidly from lock to lock several times to allow air to escape from the cylinders. When reaching the end position of the piston, do not pull harder on the steer- ing than is required for turning the steering to avoid unnecessary pressure buildup. Check fluid level while performing this opera- tion. If it continues to drop, top up until the fluid remains at a constant level and no more air bubbles rise in the supply tank when the steering wheel is turned.
With the engine running at idle, establish correct fluid level between min. Adapter High pressure hose up to bar, 1. Made locally for pressure gage item no. G e n e r a l I n f o r m a t i o n Tester pressure gage is installed between power pump and pressure line. If using old pressure gage, install in correct position. Connections and lever positions are marked for better understanding of the following instructions. Mount 1.
Install pressure gage between high pres- sure hoses and place on stand e. Make sure hose section of pressure line is not bent off.
Test hose must also have safe distance to drive belts or pulleys. Open shutoff valve on pressure gage lever position I , fill supply tank and bleed steering system see page Close shutoff valve lever position II with engine running at idle speed and read pressure.
Specification: to bar. Open shutoff valve again immediately. Turn steering wheel against left and right locks and read hydraulic pressure from pressure gage each time. Specifica- tion: to bar. It is not sufficient that only the steering stop is effective, but instead the returning force of the rotary piston valve must also be over- come.
Force on steering wheel: approx. Pull impact pad off of steering wheel with wheels in straight ahead position. Begin at bottom only 4 spoke steering wheels and outside to avoid damage. Pull off horn wires. Installing 1. Mount steering wheel with road wheels in straight ahead position or that marks are aligned in such a manner, that steering wheel spokes are horizontal.
Not applicable to airbag steering wheel see Page for marking on airbag unit on the steering wheel. See Page for removing and installing airbag steering wheel. Removing and Installing Steering Wheel. Drill out Chisel out. Tightening torque 45 Nm Replace if necessary Center the steering in the middle position with Special Tool Check the ball bearing, replace the steering rod tube if necessary Install without stresses Install without stresses.
Notes on assembly Removing 1. Remove the steering wheel see Page 48 - 17, see Page 68 - 9 for the airbag steering wheel. Loosen the cover panel on the left- hand side of the switchboard. Loosen the cover panel from the steering column switch and remove the cover for the fastening screws in the switch panel.
Undo the fastening screws for the switch panel and remove. Separate the plug con- nection. Remove the knobs from the control switch. Loosen the control switch panel carefully with a spatula. Separate the plug connection for the ignition- starter switch. Drill out the breakaway screws in the steering column housing and remove the housing.
Chisel out the breakaway screw in the protective tube and undo the hexagon head screw. Pull out the steering shaft with protective tube towards the interior of the vehicle. Remove the circlip and shim from the steer- ing shaft and pull the shaft out of the protective tube. Apply a film of Contifix to the support ring rubber bearing and slide both together onto casing tube. Install cross-link and protective tube with steering shaft.
Tighten the fastening screw between cross- link and steering shaft upper , and then tighten the fastening screw from the cross- link to the steering gear lower. Use the same number of shims to adjust the protective tube as were removed. The steer- ing shaft should be in the middle of the upper edge of the dashboard cutout and the support console. Tighten the fastening screws for the protec- tive tube.
Adjust the support bearing and tighten the fastening screws. Adjust the steering-lock housing, the spigot for the steering-wheel lock must engage easily.
Tighten the breakaway screws but do not break off. Adjust the steering column switch and mount the steering wheel briefly. There should be 2 - 4 mm play between the steer- ing column switch and the steering wheel. Once a functional and visual inspection has been carried out on all relevant com- ponents, break off the breakaway screws. Center the steering in the middle position with Special Tool and mount the steering wheel lubricating the hub with Molykote A , with the spokes horizontal.
Removal of components may change the gravity center of the vehicle. The vehicle may therefore have to be tied down by additional measures on the lifting platform. If welding or other spark-generating operations are performed in the vicinity of the battery, the battery must be removed as a rule. Rooms designated for body repairs may not be used to stock other vehicles without protection risk of fire damage due to sparks, battery, paint and body glass damage.
Be extremely careful when grinding or welding in the vicinity of the fuel tank and other parts of the fuel system. If necessary, remove any components affected. Do not weld, braze or solder any parts of the filled air conditioning system. This also applies to welding, brazing or soldering operations on the vehicle that may result in the risk of components of the air conditioning system warming up. When drying the vehicle following a respray, do not expose the vehicle to temperatures of max.
Connect ground clamp of the electric welding equipment directly and as closely as possible to the component to be welded. Make sure no electrically insulated parts are located between the ground clamp and the welding location. Do not touch electronic control units and electric lines with the ground clamp or with the welding electrode. Windshield frame corner left to corner right Front bolting points of folding top bearings Rear bolting points of side elements Windscreen wiper mounting hole - corner of windshield frame Windshield frame corner diagonally to front bolting point of folding top bearing Front bolting point of folding top mounting diagonally to rear bolting point of side element Front bolting point of folding top bearing to mounting hole of closing cylinder, center rear Front bolting point of folding top bearing to rear bolting point of side element Windshield frame corner horizontally to spot welding flange of door sill measured without cover strip Windshield frame corner to front bolting point of folding top bearing Top of B-pillar to folding top bearing Top of B-pillar, parallel, to spot welding flange of door sill From Plan 0 to fastening point of tunnel strut Fastening points of tunnel strut inside Fastening points of tunnel strut outside From Plan 0 to center of spring strut mounting.
Removing and Installing Front End Panel. Take end panel off of car forward. Move in end panel from front. Insert mounting screws. Align end panel and fenders to be in same plane. Tighten nuts and screws. Lower engine hood and adjust front panel that gap between panel and hood runs at equal distance. Raise engine hood and tighten screws.
Separate spot welding joins of rear end-panel to end element and to spare wheel recess pane. Separate spot welding joins of end-panel to end element and spare wheel recess panel using welding spot cutter. Cut through inert gas welding seams between end-panel and end element using a bodywork saw.
Separate spot welding joins of end-panel to side panels using a welding spot cutter. Cut through welding joins of end-panel to side panels using a bodywork saw.
Clean paint etc. Remove the factory-ap- plied primer on the welding surface of the replacement part end-panel using a rotary brush. Drill holes in the end-panel at the join points to the end element and the spare wheel recess panel for plug weld- ing. Drill holes in the spot welding flange in the side panels for plug welding to the end-panel. Fit end-panel into bodywork and tack weld Assemble tail lights and bumper to check body contours.
Fit end-panel into bodywork, align it, fasten with clamp- ing tools and tack weld using inert gas. The body contours with the tack-welded end-panel must fit in with the contours of the tail lights and bumper.
Re- move tail lights and bumper again atter checking. Align end-panel with end element and spare wheel recess panel and plug weld using inert gas. Align end-panel with end element and butt weld along the whole seam using inert gas. Weld end-panel at hori- zontal joins with side panels along the whole seam using inert gas.
Align side panels with end-panel in the areas of the spot welding flanges and plug weld them using inert gas. Spot weld end-panel to spare wheel recess panel in the areas of the tail lights and number plate.
Cut through inert gas welding seams between side panel and end-panel and inert gas welding seam be- tween side panel and inner side panel using a bodywork saw. Separate spot welding joins of side panel to end-panel, inner side panel, wheel arch and door sill connection element.
Separate spot welding joins of side panel to end ele- ment, inner side panel, wheel arch and door sill connec- tion element using a welding spot cutter. Remove side panel. Clean underseal, paint etc. Remove the factory-applied primer on the welding sur- faces of the replacement part side panel using a rotary brush.
Fit side panel into bodywork, align it, fasten with clamp- ing tools and tack weld using inert gas. The body contours with the tack-welded side panel must fit in with the contours of the tail light, bumper and door.
The gap between the door and the side panel must ex- hibit a parallel shape. Remove the door, tail light and bumper again after checking. Weld side panel to inner side panel with inert gas Spot weld side panel to inner side panel Plug weld door sill connection element to side panel. Align side panel with inner side panel and intermittently weld along the whole seam overlapped using inert gas. Align side panel with inner side panel area of B-pillar and spot weld.
Align door sill connection element with side panel and plug weld using inert gas. Spot weld side panel to inner side panel, wheel arch and door sill connection element. Align side panel with inner side panel, wheel arch and door sill connection element and spot weld. Weld side panel to end element using inert gas Spot weld side panel to end element and wheel arch Plug weld side panel to end element.
Align side panel with rear end element and butt weld along the whole seam using inert gas. Align side panel with rear end element area to one side of tail light and spot weld.
Align side panel with wheel arch area of bumper and spot weld. Align side panel with rear end element area of tail light and plug weld using inert gas. The stamping area for the striker was enlarged on the outer rear side panels as of MY ' Before fitting a new outer rear side panel into a vehicle up to MY '91, the inner rear side panel has to be modified in the striker stamping area.
When fitting a new outer rear side panel, it is also recommended to fit a new striker and a new striker pin. N o t e : The crank on the drive motor has to be moved to top dead center for adjustment of the cable.
Procedures: 1. Contact positive pin red wire of plug section for wire harness with other end of lead briefly, until crank on motor has reached top dead center. Adjusting Electric Tailgate Unlocking Cable. Removing and installing the tailgate lock microswitch 1. Removing and Installing Engine Hood. Disconnect electric plugs for windshield spray jet heating and engine compart- ment light, and take wires out of holders.
Lift with second person hood on to car, install and tighten mounting bolts finger tight. Lower hood and align to have equal clearance between fenders and front panel. Raise hood and tighten mounting bolts. Support front end of engine hood. Clip gas pressure props in the ball heads. Compress gas pressure props slightly do not press up hood to avoid damaging the windshield and guide into gas pressure prop take-ups. Compress gas pressure props to align them with the take-up bores and insert the bolts.
Clip retainers in grooves of bolts. Secure hose for windshield washer in holders and on washing fluid tank. Connect electric plugs and secure wires in holders. If the hood does not open when the hood release handle is pulled, proceed as follows: 1.
Open internal mechanism with a suitable tool, slide inside door handle into guide and clip in retainer. Removing and Installing Inside Door Handle. Remove hoods, unscrew fastening screws for door paneling, loud- speaker aperture, storage tray, and the switch aperture. Dis- connect electrical plugs. I n s t a l l a t i o n Installation is in reverse order.
Removing and Installing Door Paneling. R e m o v a l N o t e Before removal, the door panel, film, and door window must be removed. Pull window guide out of window guiderail. Unscrew the upper and lower fastening screws and pull window guiderail out from below. I n s t a l l a t i o n Installation takes place in reverse order. Before removal, the door paneling, door film, door window, and window guiderail must be removed.
Push outside door handle forward and detach from outer door panel. Unclip connecting and actuating rods on lock. Unscrew cable- bracket screw and carefully un- clip microswitch with suitable tool. Removing and Installing Outside Door Handles. Before removing the inner parts, the door paneling, door film, door window, and window guiderail must be removed. Central Locking System. Note setting Clip on securely.
Removing and installing central-locking control unit The control unit is mounted beneath the instrument panel and is attached to the steering column by a metal holder. Removing and installing actuator Removing 1. Screw holder on to actuator and tighten until it is just possible to move actuator.
Bolt holder with actuator into position inside door and tighten so that holder can still be moved. Hold the linkage of the locking button to keep door lock in open position. Push actuator forward in slots of holder and tighten bolts.
Slacken mounting bolts of holder slightly and move actuator toward rear in slots to obtain reserve travel. Tighten mounting bolts. Removing and installing microswitch in door lock cylinder 1. N o t e The testing of the central locking system and the localizing of a defect can be carried out on the pin plug of the control unit without extensive disassembly and assembly.
Make up 2 short auxiliary cables with 2. Use circuit diagram , turbo sheet 10, page 97 - Central Locking System Troubleshooting. Reverse connections at terminals 3 and 4, in other words, briefly connect plus to ter.
The actuators must unlock. Checking operation of microswitches in the actuators Set both doors to the open position. Connect a continuity tester across terminals 10 and 5. Lock and unlock the door locking button of each door in turn. In the locked position, the tester must show continuity. Lock both doors. Connect continuity tester across terminals 2 and 5. Unlock and lock doors at locking buttons. In each case, the tester must show continuity in the unlocked position.
Checking operation of microswitches in lock cylinders Connect continuity tester across terminals 5 and 7. Use key to turn lock cylinder of each door toward "open". In each case, the tester must show continuity.
Remove lead from ter. Turn lock cylinders toward "closed". Checking operation of push button switch in central console Connect continuity tester across ter.
When the pushbutton switch is actuated, the tester must show continuity. Use a length of wire to connect ter. Switch on position lights. The key symbol in the switch must be illuminated. The electrically operated and removable sun roof can be opened in infinite steps up to final position with a switch in the center console after turning on the ignition.
R e m o v i n g R o o f The roof should be cleaned first to avoid scratching the roof on deposits of dirt while removing. Turn off ignition and push back a tumbler switch until drive elements unlock the roof. Working On Electric Sun Roof. Turn off ignition and push tumbler switch forward b until drive elements lock the roof. Turn the now visible threaded sleeve anticlockwise with the wrench until the roof is closed.
Replace assembly set. Check and adjust clutch. Replace dog. Replace pinion on motor. Gates loose. Screws of assembly set loose. Roof fasteners and centering wedges loose. Wind deflector loose. Check gates, replacing if necessary. Tighten screws. Swing electric drive into inside of car slightly. Unscrew cover mounting screws and remove cover.
Jobs on Power Sun Roof. Pull off edge guard partially arrow. Loosen roof liner on body partially. Guide long pipe of assembly set into assembly opening of body. Slide pipe through the C pillar by turning the entire part. Never use force, the pipe must not be bent. Bolt rear end of element guides on roof hoopsticks without tension. Adjust front mounting points of element guides see adjusting sun roof. The pipe with the raising cable must protrude into the trunk parallel to the side panel.
If these distances are not reached, the assembly set has to be replaced. Adjustment of the raising cable is not possible. It must be possible to move the raising cable back and forth by hand. Work drive with raising cable into guide rail of electric drive, route along the rail and clip on counterpiece in cam. Engage console of electric drive in rear frame profile, screw on nuts and plug console claws on edge guard.
Tighten all nuts. Lifting sun roof removed. Trim on rear roof frame removed. Edge guard and roof liner on rear roof frame loosened on body partially see "Removing Electric Drive and Assembly Set" - points 6 through Place edge guard on collar, install roof, arrest and adjust element guides in slots that lifting roof lid and car roof are in same plane. Tighten mounting screws. Remove roof and pull off edge guard, cement roof liner on body and slide on edge guard. Screw trim panel on roof frame and install caps on heads of screws.
The gates bolted on the lifting roof lid have slots, with which the lifting roof lid and car roof panel can be adjusted to be in the same plane. Check gate guides, replacing if worn or damaged. Cable anchors located in the lifting roof lid must be adjusted that the cable of the lifting roof runs parallel to the cable of the car roof.
Should the lifting roof lid protrude at the front, the centering wedges must be unscrewed on the roof beam and installed again with washers underneath. Spread clamping sleeve with a suitable pliers and take off clamping sleeve and drive dog. Clamp clamping sleeve to distance on the raising cable and with the gap in alignment with beads on the pipe. Adjust drive dog on raising cable and install screw with washer on raising cable.
Drive dog must be aligned with beads on pipe. Install electric drive. Take sun roof switch out of center console with help of a spatula. Unfold plug connection cover for switch. Terminal 3 must have battery voltage with the ignition turned off and the ignition key inserted radio position. Check microswitch in roof opening. N o t e The microswitch will prevent running out the lifting elements unintentionally after removing the roof.
Check microswitch - see next page. Microswitch must remain in closed position with the roof installed up to the maximum lifting position. The switching point can be identified by a loud "click". The roof cannot be lifted when the microswitch is open or a wire is interrupted. If fuse is okay, loosen trim panel in luggage compartment at rear left and pull off relay on sun roof drive. Unlock and remove lifting roof lid. Disengage operating flap in lifting roof mount with a body spatula.
The slip clutch was adjusted in the factory and only has to be readjusted, if the adjusting screw had been removed for manual operation of the roof. The lock nut is cemented on the adjusting screw at a distance of 2. To guarantee perfect operation of the slip clutch, the adjustment should be made by measuring the power input of the sun roof motor. Turn on ignition and operate switch to move lifting roof lid to final position of drive.
Measure power input in final position clutch slips. Screw mounting nuts off the threaded studs and dis- engage electrical drive from its mounting locations. Move electrical drive aside and disconnect plug connec- tors. Loosen fastening screws housing of electrical drive and remove cover.
Unclip yoke from switching cam and remove yoke complete with lift cable from guide rail. Separate spotwelds between support panels and roof rail using a spotweld cutter. Separate MIG weld seams between support panels front side and roof rail. Right-hand side only: Enlarge cutout for drain hose in the body panel just enough to allow the short tube - in- cluding the covering - of the mounting assembly to be introduced into the cutout.
Drill a 7. Positioning the left-hand adapter plate: Center of vehicle to center of adapter plate Positioning of right-hand adapter plate: Center of vehicle to center of adapter plate Drill blind rivet holes in roof rail. Fit connector and connecting tube to lift cable. Use con- nector to install tube assembly kit and connecting tube. Screw yoke to lift cable. Turn protruding section of lift cable to adjust length to mm measured between connecting tube and yoke.
Note: When adjusting, the arc segments must be engaged to stop into the segment guides. Insert yoke complete with lift cable into guiding sleeve of the electrical drive and clip into actuating cam. Insert connecting tube into housing, install and tighten cover. Close connector for electrical drive. Engage electrical drive into mounting points and tighten. Glue roof liner to edge of body panel roof aperture , put edge protector back on and install roof lining.
Lifting sun roof as from February General A new lifting sun roof lifting system has been in use from February onwards. Opera- tion of the new lifting sun roof has not changed in comparison with the previous ver- sion. Closing lifting sun roof manually: Should electric lifting sun roof operation fail, the roof can also be closed manually.
The drive motor is located behind the carpet on the left side section of the luggage compart- ment. Open the flap on the luggage compartment cover. Remove securing screw of the round rubber buffer, release clips on the carpet and fold carpet back. Remove cover cap. Plug the ignition plug wrench included in the on-board tools onto the now visible hexagon nut and tum in clockwise direction until the lifting sun roof is closed.
Lifting sun roof - removing and in- stalling electric sun roof drive and assembly set Removing 1. Open tailgate and flap on the luggage com- partment cover. Unscrew securing screw of round rubber buffer, remove trim panel clips and place trim panel aside. Lifting sun roof - removing and installing electric sun roof drive and assembly set Printed in Germany - XVI, Swing electric drive into inside of car. Un- screw mounting screw and hexagon nuts on raising cable.
Disconnect connector from electric drive. Detach connecting tube with raising cable from pinion housing and also detach electric drive. On guide tube, press clamping sleeve in the tube's longitudinal direction and extract con- necting tube with clamping sleeve.
Guide long pipe of assembly set into as- sembly opening of body. Slide pipe through the C pillar without using force. Secure element guides with brackets in holders on both sides lightly in the roof beam.
Slide element guides home into the brackets and adjust parallel to each other in accord- ance with the specified distances. Tighten rear screws. Check dimensions in the ex- tended and retracted positions of the ele- ments and readjust if necessary. Tighten front nuts. Plug connecting clip onto the raising cable and install the clamping sleeve using special tool " ".
Plug clamping sleeve home on connecting and guide tube. Adjust raising cable with elements retracted home and in accordance with the specified dimensions. Turn clockwise for a longer dis- tance and counterclockwise for a shorter dis- tance.
Carefully work the connecting tube with rais- ing cable on the electric drive into the pinion and pinion housing and secure with hexagon nuts. Guide raising cables through the trailing lever, insert into the square hole in the swing lever and secure with the screw.
Join connector halves. Insert lifting sun roof and, if necessary, ad- just on front and rear adjusting bolts until lift- ing sun roof runs level with the roof. If necessary, adjust the adjusting screws of the element guides so that the elements travel into the gates with large-scale tension. If the elements are not in zero position, deviations must be equalized by adjusting microswitches on the electric drive.
The gates bolted on the lifting roof have slots with which the lifting roof and car roof panel can be adjusted to be in the same plane. To increase stability of shape, lifting sun roof has been reinforced on the inside by ad- hered aluminium profiles. The pull anchors have been dropped. Should the lifting roof protrude at the front, the centering wedges must be unscrewed on the roof beam and installed again with washers underneath. Removing and installing raising cables and elements 1.
Remove electrical drives. See Lifting sun roof - Removing and installing electric sun roof drive and assembly set. Pull element out of the element guide. Grease new element and insert home.
Use special grease. If you have a problem that's covered, it's great. I also have a copy of the Haynes manual and it's mostly worthless. Porsche Introduced in the market in and produced till , the Porsche was an entry level sports car from German automaker Porsche. The was intended to last into the s, but major revisions planned for a 'S3' model were eventually rolled into the instead, which replaced the This play cannot be measured; it is about 3 mm at the pedal pad and must be determined by feel.
If necessary, correct play by adjusting piston rod. For this purpose, the spring must be preloaded accordingly. Measure distance A between outer edge of plate and bearing with clutch engaged clutch pedal at end stop.
Remove cap see page 30 - 2. Measure distance "B" with a suitable measuring tool. Switch on bleeder and open bleeder screw on clutch slave cylinder until escaping fluid is without air bubbles.
Operate clutch pedal several times during this step. If necessary because of residual air release traver less than 15 mm , unscrew slave cylinder on clutch housing. Push rod against stop in slave cylinder and release again bleeder switched off, brake fluid tank not filled to upper edge. Note When performing operations on the transaxle system that involve rotating or shifting the transaxle tuebe, always wear leather gloves to avoid injuries.
Disconnect ground wire at battery. Disconnect round wire connecting body with clutch housing. Disconnect ground wire on clutch housing I. Disconnect wire harness for starter at upper mounting point V. If necessary, remove air cleaner for this step. Remove exhaust assembly. This requires unscrewing exhaust pipe on exhaust manifold and suspension mounting bolts.
If car has oxygen control, disconnect wires of oxygen sensor on plug. Remove heat shield above catalytic converter. Remove splash guard. Run out rear exhaust pipe bracket together with bracket bolted on the central tube.
Lift and fold down dust cover and sleeve on shift lever. Remove shift lever knob retainer. Take off shift lever knob. Remove insulator above shift lever console. Remove shift lever, but first mark location of console after removing the rear mounting bolt.
Press down on insulation sheet and push selector rod forward in cavity by about mm 12 in. Take off end cap on central tube housing. Push back protective tube for selector rod far enough, that it is outside of the central tube housing.
This is done by inserting a large screw- driver through assembly opening in central tube housing and opening retainer on protective tube. Unscrew and remove clamping sleeve bolts through assembly openings. Push clamping sleeve in direction of transmission. Detach joint shafts on transmission end, but do not let joint shafts hang down to final stop in joint instead suspend from car with wire to avoid damage.
Pull off wires on backup light switch. Run in a workshop trolley jack fitted with Special Tool or an universal trans- mission jack underneath the transmission. Lift transmission slightly to remove pressure on suspension. Lower transmission with central tube until central tube rests on the rear axle cross tube. Remove starter. Unscrew clutch line mounting clamp, Detach clutch slave cylinder on clutch housing do not open hydraulic system.
Disconnect starter wire harness on clutch housing. Pull out release lever shaft mounting bolt with a 8 mm bolt. Pull back selector rod again, which had been pushed forward for removal of the transmission, so that nothing will be damaged when moving the central tube. Move back central tube far enough until central tube housing rests on transmission carrier.
If central tube cannot be moved out of clutch housing without applying force, hold engine tight with transport eye mounted on camshaft housing with Special Tool VW In this case the engine has excessive inclination at rear - check engine suspension. N o t e Make sure brake lines are not damaged by the central tube. Unscrew guard on clutch housing. Remove right support, insofar as car is fitted with supports. Unscrew two lower mounting bolts on clutch housing, after unscrewing engine mount nuts and pushing engine to the right.
Check flywheel, starter gear ring, pilot bearing in flywheel, crankshaft seal, release bearing, guide sleeve, release lever, pressure plate and clutch disc for wear or damage.
Coat guide sleeve with multi-purpose MoS 2 grease. Lubricate release lever pivot, ball socket and needle bearings with white solid lubricating pasta AOS Install clutch.
This requires that friction surfaces be clean and without grease. Use short drive shaft of a or a shortened drive shaft from a damaged central tube to center the clutch disc. Screw in bolts uniformly crosswise. Counterhold on hexa- gon bolt of front pulley. This requires that the bolt glued on the flywheel for the reference mark sensor faces down danger of damage. Insert cover. Mount clutch housing with the two lower bolts.
Move release lever until needle bearing and bore in clutch housing align. Slide in release lever shaft positioned correctly so that machined surface faces mounting bolt against stop. If necessary, move release lever back and forth - but never use force! Screw in mounting bolt for a correctly installed release lever shaft and lock with out.
Bolt clutch housing, cover and, if applicable, right support. Connect starter wire harness. Mount start and reference mark sensors as well as ground wires on clutch housing and body. Check that insulation sheet on central tube is still positioned correctly. Distance from flange inside to insulation should be mm 20 in. Push central tube forward and bolt on clutch housing. Guide central tube with drive shaft into clutch housing and clutch disc carefully danger of damage.
Never apply force. Screw in mounting bolts and loosen again by about 1 turn. Never tighten bolts fully, see note! Place selector rod protective tube in trans- mission case.
Replace a selector rod protective tube, if retainer is deformed excessively. Install transmission. Push selector rod protective tube forward until retainer engages in transmission case. Mount selector rod on intermediate shift lever. Tighten mounting nuts insofar as engine mounted had been unscrewed.
Then bolt central tube on clutch housing to specified torque bolts had only been screwed in finger tight. Repair any damage on splash guard caused by removal of transmission or moving of central tube.
Install starter and exhaust assembly. Do not operate clutch pedal after removing cylinder line connected Pull out with a 8 mm bolt stud. Refer to point 8 Refer to point 8.
Do not use force! Move release lever back and forth slightly through sight hole. Inspect splines. Drive plate must slide easily on input shaft in axial direction without radial play. Check rivets and rubber torsion damper for cracks or damage. Replace drive plate when in doubt. Inspect clutch liners. If clutch liners are covered with oil, burnt, damaged or worn at spots, install a new drive plate. Check liner thickness of drive plates. Drive plate with riveted liner: Relaxed thickness: 8.
Relaxed wear limit: 6. Check drive plate with liner for lateral runout. Make sure of perfect fit Replace Replace. Check bearing sleeve visually for damage. Checking Torque Converter Type N. Drain the torque converter when ATF has abrasive particles or for a general overhaul. Connect a suitable hose max. Squeeze plastic bottle slightly and insert free end of hose into converter hub until it touehes bottom.
Place converter on one-way clutch support care- fully; not tilting the converter. Remove catalytic converter together with muffler. Push down on insulation sheet and push selector rod forward in tunnel cavity by about mm 12 in. Remove end cap on central tube housing and push back selector rod far enough, that it is outside of the central tube housing. This requires pressing in the retainer on the protective tube with a large screwdriver applied through opening in central tube housing.
Removing and Installing Transmission Type K. Unscrew clamping sleeve bolts through openings and push clamping sleeve in direction of transmission. Place universal transmission jack underneath the transmission and secure retaining strap. Lower transmission with central tube until central tube rests on rear axle cross tube. Remove transmission from below. Place selector rod protective tube in transmission case. Tighten and bolt transmission. Tighten all mounting bolts to specified torque see page 30 - Turn shift lever Press down on insulation sheet and push shift rod forward into produced cavity by about mm.
Unscrew clamping sleeve screws through assembly openings and push clamping sleeve toward transmission. Push back protective tube through large opening in case far enough, that it is outside of the central pipe housing. Press in retainer with a large screwdriver for this purpose.
Hold transmission and central pipe in installed position, placing proper size wooden block between cross tube and central pipe for this purpose. Place shift rod protective tube in trans- mission case. Run in transmission and bolt. Shift lever should be in neutral for this adjustment. Shift lever in neutral. In this position a spring will hold the lateral selector shaft I in the center shift plane 3rd and 4th gear.
When shift was adjusted correctly, shift lever will not have lateral inclination. Adjustments are made on intermediate shift lever for joint rod. Adjusting Shift Linkage.
Capacity: Approx. Drain transmission oil of a car parked on level ground or floor and transmis- sion having operating temperature. Note The fluid level in the transmission housings used in production is approx. Special Instructions. Remove trans- mission before removing. If transmission case has to be replaced and deviation "r" is not on ring gear, check location of drive pinion before removing gear carrier actual distance.
R e m o v i n g N o t e The differential need not be removed for jobs on the gear carrier. If the transmission case or tapered roller bearing for the drive pinion has to be replaced and deviation "r" is not given on the ring gear, measure actual location of drive pinion befare removing the gear carrier.
Unscrew selector lever bolts and remove complete selector shaft do not disassembly. Slide Special Tool on spline of input shaft and install gear carrier with set of gears in transmission case. Insert a large screwdriver into center of rubber cover and pry out Drive off with a plastic hammer Pull off with a two-arm puller.
Replace Torque:. Pull off with a two-arm puller Note thickness Do not loose small lock pin. Remove end cover by puncturing center of rubber with a large screwdriver and prying off cover. Drive out 5th gear selector fork dowel sleeve. Hold with a hammer so that selector rod bore in end bracket is not widened. Remove circlip for synchronizer. Remove 5th gear with sliding sleeve and synchronizer, needle bearing and 5th gear selector fork. Selector rod remains in gear carrier! Unscrew stop bolts for selector rods.
Make sure vise is fitted with soft jaws! Two-arm puller standard e. Drive out dowel sleeve for dog on 1 st and 2nd gear selector rod, while holding with a hammer. Turn dog to face up. Pull out selector rod for 3rd and 4th gears selector fork remains in sliding sleeve. Do not loose small lock pin! Pull drive pinion and input shaft forward slightly. Remove input shaft with 3rd and 4th gear selector fork. Pull drive pinion forward far enough so that selector rod and selector fork for 1st and 2nd gears can be removed.
Adjust operating lever see page 34 - Slide in 3rd and 4th gear selector fork positioned correctly on selector rod for 5th and reverse gears. Install input shaft, insert 3rd and 4th gear selector fork in sliding sleeve and push in input shaft completely. Adjust selector rods to neutral position and make sure rocks are positioned correctly see page Slide in 3rd and 4th gear selector rod with small lock held in position with grease.
Lock dog for 1st and 2nd gear selector rod on selector rod with a pin, while holding with a hammer. Determine thickness of shim for 5th gear.
Measure distance "a" with a depth gauge and refer to foltowing table for thickness and part number of shim. If necessary, knock on against stop with a suitable mandrel. Lubricate cylindrical rollers of input shaft bearing with a little grease and press outward. Determine thickness of circlip for cylindrical roller bearing inner race.
Use and install the thickest possible circlip. Axial play may be max. The following circlips are available. Part Number. Mount 5th gear with synchronizer and sliding sleeve, needle bearing and selector fork. Lock selector fork on selector rod with a pin, holding with a hammer. A - Inner race of ball bearing.
Only available as complete spare part Torque: 30 Nm Replace Torque: 30 Nm Adjust operating lever and torque bolt to 35 Nm Adjust Torque: 24 Nm Connect single angled end in recess of synchro- mesh ring.
Turn double angled end to left and eonnect in end bracket through opening. Since Aug. Synchromesh ring Reverse gear Cylinder roller bearing, outer race Tapered roller bearing, outer race Shim S 4 End plate.
Press out with b Press out suitable pipe section e. VW Note thick- ness for re- installing. Check for wear Press in to correct position with b Press in with VW Determine new thickness if necessary If replaced, determine new thickness for shim S 4. Press in cylindrical roller bearing outer race to correct position with P b. Check synchromesh ring.
Press synchromesh ring on cone of gear and measure clearance "a" with a feeler gage blade. Clearance "a". Adjust operating lever. Insert reverse gear lock. Insert selector rod for 5th and reverse gears as well as operating lever in correct position.
Press operating lever in direction of arrow until it rests on selector rod and dog of gear. Screw in bolt and tighten to specified torque. Engage reverse gear several times and check that all points of reversing mechanism mave easily. N o t e: Operating lever has been adjusted correctly when it is centered exactly above bushing for reverse gear lock.
Installed position of locks and 5th gear detent. It provides preload for the drive pinion's tape red roller bearings.
Measure case depth "a" of old and new gear carrier housing and determine difference. Example: Old gear carrier housing depth "a". Shims available as spare parts: Thickness mm. Disassembling and Assembling Transmissions Case. Pult out with VW Pult off Press down retainer with a smalt screw- driver applied in vent pipe and pull out deflector. Pult out with VW Pack space betw. Replace; pack space between sealing tips with multi-purpose grease. Drive in to stop with VW Give sealing lip a light coat of oil drive into case to depth of 1.
First install gear set to avoid damaging seal. Drive in flush with VW Do not mix up with needle bearing no. When replacing, measure installed position actual distance of drive pinion befare removing. Drive out with VW and VW Note thickness for installation later When replacing, measure installed position actual distance of drive pinion befare disassembling. Heat case and press in with VW and VW Determine new thickness if necessary. Remove front needle bearing for input shaft with an internal claw puller, e.
Remove rear needle bearing for input shaft with an internal claw puller, e. Pult out outer race for smalt tapered roller bearing. Use a 46 to 56 mm internal claw puller and spindle for this step. Pult out outer race of large tapered roller bearing with a 46 to 56 mm internat claw puller and spindle. Install tapered roller bearing outer race for drive pinion in the heated case.
Always work with a press to avoid tilted. Hold preload under press about 2 more minutes until heat has been transferred. Press in outer race for small tapered roller bearing in side cover. It is recommended to heat to cover. N o t e It is recommended to install the seals for flange shafts only after installation of the differential to avoid damage. Circlip pliers Feeler blade gauge Press plate Pipe Separator. Determine new thickness Adjust axial play Lubricate with gear lube Spray molybde- num on friction surface.
Check for wear. Determine new thickness Position correctly Check axial play Position correctly Spray molybde- num on friction surface. Check axial play betw. Install only after installing input shaft. Since September, the thrust ring No.
The circlip No. Old and new parts or vice versa may not be installed with each other for repairs. Adjusting the axial play on the fourth gear has been omitted. Assemble sliding sleeve and synchronizer for 3rd and 4th gears.
It is not necessary to have a pair in a certain position, how- ever, groove in synchronizer or wide collar of hub must face 4th gear. Press on sliding sleeve with synchronizer body in correct position, turning synchromesh ring so that grooves are aligned with locks. Measure axial play of synchronizer body with a feeler gauge blade and adjust by selecting a pertinent circlip. It should be between 0 and 0. Measure play between 2nd and 3rd gears. Nominal value: 0. If this tolerance cannot be reached, recheck adjustment of synchronizer.
Measure axial play on 4th gear with a feeler gauge blade and adjust with a pertinent circlip. Play should be between 0. Clean synchronizer rings and gears. Press dried synchronizer rings on tapers of gears and measure clearance "a" with a feeler gauge blade.
Tapered roller bearing 1st gear Needle bearing Synchronizer ring for 1st gear Circlip Synchronizer with sliding sleeve for 1st and 2nd gears Sliding sleeve Synchronizer body Spring Lock Synchronizer ring for 2nd gear 2nd gear Needle bearing Circlip.
If necessary, replace both bearings together. Identification: each 3 x 1 tooth missing. Friction surfaces coated with molybdenum and spiral groove.
Press off with separator. Install warm and press on. Large collar faces 2nd gear. Adjust axial play. Thickness always 2. Large collar faces 3rd gear. If necessary.
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