Volkswagen Golf Variant / Jetta. Manual - part 5

 

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Volkswagen Golf Variant / Jetta. Manual - part 5

 

 

1 - Bonnet

❑ Removing and installing

⇒ page 17

❑ Adjusting 

⇒ page 25

2 - Adjustment buffer

❑ Qty. 2
❑ Adjusting 

⇒ page 25

3 - Stop buffer

❑ Qty. 2

4 - Insulation

❑ Removing and installing

⇒ page 20

5 - Guide

❑ Qty. 2

6 - Lid hinge

❑ Removing and installing

⇒ page 19

❑ Adjust bonnet

⇒ page 25

 .

7 - Gas strut

❑ Removing 

⇒ page 19

❑ Releasing gas

⇒ page 19

8 - Seal

❑ Secured to inner bonnet

with clips

1.3

Removing and installing bonnet

1.3.1

Removing

– Remove left and right washer jets -6- ⇒  Electrical system;

Rep. Gr.  92 ; Windscreen washer system .

– Unclip line -2- from bonnet hinge -3- and bonnet -5-.
– Pull line -2- out through aperture in bonnet -5-.
– Loosen hexagon nuts -1- on left and right (do not remove).
Further dismantling requires the assistance of a second mechan‐

ic.
– Disconnect gas strut -4- from bonnet -5- 

⇒ page 19

 .

1. Bonnet    

17

 

1.3.2

Installing

Install in reverse order of removal.
Specified torque for bonnet hexagon nut: 22 Nm.
Adjusting bonnet -1- 

⇒ page 25

 .

– Route line -2- in an arc -arrow-. If line is installed twisted it will

kink.

18

 

– Open bonnet and support it.
– Position a small screwdriver beneath spring clip -2-.
– Raise spring clip -2- until it can be moved over ball socket in

direction of -arrow-.

– Pull gas strut -1- off ball-head pins -3- and -4-.
– Slide spring clip -2- back immediately after removing gas strut

-1-.

WARNING

Proceed with care if gas strut is reused. Spring clip must not

be levered completely out of ball socket, as it will otherwise be

damaged. Gas strut will spring out of mounting, causing dam‐

age or injury to operator.

Specified torque for ball-head pins -3- and -4-: 22 Nm.
Releasing gas from gas strut 

⇒ page 19

1.5

Releasing gas from gas strut

– Clamp gas strut in vice in area marked -x- = 50 mm (2 in).

WARNING

Clamp gas strut only within area -x-; otherwise danger of ac‐

cident!

– Saw through cylinder of gas strut within first third of cylinder's

overall length using piston rod end of cylinder as reference

point.

Note

Wear eye protection when sawing.

Cover area of saw cut with a cloth.

Dispose of oil and cloth via existing disposal channels.

1.6

Removing and installing lid hinge

Note

The removal and installation sequence is only described for the

left hinge. The removal and installation of the right hinge is similar.

1. Bonnet    

19

 

– Remove front bonnet 

⇒ page 17

 .

– Remove bolts -2- and remove bonnet hinge -1-.

1.6.2

Installing

– Install lid hinge -1-.

Specified torque for bolts -2-: 22 Nm.

– Install bonnet 

⇒ page 18

 .

1.7

Removing and installing insulation

1.7.1

Removing

– Lever retaining clips -1- out of insulation -2- using removal

lever -80-200- .

20

 

 

 

 

 

 

 

 

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