Volkswagen Golf Variant / Jetta. Manual - part 109

 

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Volkswagen Golf Variant / Jetta. Manual - part 109

 

 

and then disconnect it.

– Remove bracket from lower starter bolt.
– Remove the lower starter bolt and then remove the starter.

Cooling System Components; Coolant, Draining and Filling .

– Turn the cap -1- in the direction of -arrow- and remove it.

– Remove the six converter nuts -arrow- with the Socket - Sw15

- V/175- .

Note

Carefully rotate the engine further!

6. Transmission, Removing and Installing, Jetta from 2005, Golf Wagon from 2007, Jetta Wagon from 2008    

67

10-222A/7- on the cylinder block.

– Remove the coolant hoses from the ATF cooler.
Tension the right spindle one turn (more turns are not necessary).
– Support the engine and transmission with the left spindle. Do

not lift.

– Remove the transmission mount bolts -2- to the transmission

bracket -A- and remove the transmission bracket bolts -1- to

the transmission.

– Remove the transmission bracket -A-. To do so, slightly lower

the engine with the transmission using the spindles of the En‐

gine Support Bridge - 10-222A- .

Four turns are sufficient.
– Remove the lower engine/transmission connecting bolts.
– For safety, leave one bolt installed that is easily accessible.

– Before removing the last connecting bolt, support the trans‐

mission with the Engine and Gearbox Jack - VAS6931- , the

Transmission Support - 3282- and the Transmission Support

- Mounting Plate 36 - 3282/36- .

– Use the bolt -1- to secure the transmission to the Transmission

Support - 3282- .

– Remove the last bolt.
– Press the transmission off of the engine, at the same time

press the torque converter off of the engine drive plate.

– Make sure there is enough clearance around the subframe

while lowering. Adjust the Transmission Support - 3282- slight‐

ly, if necessary.

68

The connector on the transmission must not be damaged

when removing and installing the transmission. Replace the

wiring harness in the transmission if the connector gets dam‐

aged. Refer to 

⇒ “4.1 Overview - Valve Body”, page 128

 .

Pay attention to the torque converter. It must be removed to‐

gether with the transmission. Secure the torque converter

with, for example a wire -A- to prevent it from falling out.

Bear in mind that when installing a new transmission, the cable

bracket and the selector lever cable bracket for example must

be replaced.

6.4

Transmission, Installing, Vehicles with

2.5L - 110 kW and 2.5L - 125 kW En‐

gines

– Check that the alignment sleeves are pressed into the engine

flange.

– Make sure the intermediate plate fits correctly between the

engine and the transmission. The plate must contact the en‐

gine along entire perimeter when pressing lightly against en‐

gine using both hands. If it is above the engine, then it is not

hooked into the cylinder block correctly.

– Make sure the torque converter is installed correctly. Refer to

⇒ “1.1 Torque Converter, Removing and Installing”, page 10

 .

Further installation is performed in the reverse order of the re‐

moval.
The engine and the transmission must be mounted in the sub‐

Removing and Installing for the procedure description.
– Replace all the bolts from the left subframe mount.
– Install all new bolts first by hand.

6. Transmission, Removing and Installing, Jetta from 2005, Golf Wagon from 2007, Jetta Wagon from 2008    

69

mission bracket -A- on the transmission.
– Align the engine/transmission in its installed position. Lift until

the transmission bracket is touching the transmission mount

completely.

Caution

There is a risk of damaging the threads in transmission bracket

by inserting bolts at an angle.

♦ Before installing the bolts -2-, the transmission bracket

and transmission mount support arm must be absolutely

parallel to each other. If necessary, lift the back of the

transmission using the Engine and Gearbox Jack .

Adjust the »old fit« between both bolts using a screwdriver when

tightening the transmission bracket to the transmission mount

bolts -2-. Tighten the two larger bolts to 60 Nm +90°.
Transmission to engine tightening specifications. Refer to

⇒ “6.5 Tightening Specifications, Transmission to Engine”,

page 71

 .

– Install the pendulum support. Refer to ⇒  Suspension, Wheels,

Steering; Rep. Gr.  40 ; Subframe; Overview - Subframe .

– Attach the drive axles to the transmission. Refer to ⇒  Sus‐

pension, Wheels, Steering; Rep. Gr.  40 ; Drive Axles, Re‐

moving and Installing .

26 ; Exhaust System; Exhaust System, Installing without Ten‐

System, Installing without Tension .

– Install the starter. Refer to ⇒  Electrical Equipment; Rep. Gr. 

27 ; Starter; Starter, Removing and Installing .

– Connect the coolant hoses to the ATF cooler and check the

– Attach the selector lever cable to the transmission and adjust

it. Refer to 

⇒ “4.5 Selector Lever Cable, Adjusting”, page 38

 .

– Install the battery tray and the battery. Refer to ⇒  Electrical

Equipment; Rep. Gr.  27 ; Battery; Battery, Removing and In‐

stalling .

– Check the ATF level after installing. Refer to

⇒ “11 ATF Level, Checking and Filling”, page 112

 .

50 ; Noise Insulation .

– Install the wheels. Refer to ⇒  Suspension, Wheels, Steering;

Rep. Gr.  44 ; Wheel Installation Tightening Specifications .

– Perform a basic setting. Connect the Vehicle Diagnostic Test‐

er and then select “Perform basic setting” under 

Guided

Functions

.

Tightening Specifications
Transmission to engine tightening specifications. Refer to

⇒ “6.5.2 Tightening Specifications, Vehicles with 2.5L - 110 kW

and 2.5L -125 kW Engines”, page 73

 .

Component

Nm

Drive plate to torque converter

60

70

 

 

 

 

 

 

 

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