Volkswagen Golf Variant / Jetta. Manual - part 145

 

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Volkswagen Golf Variant / Jetta. Manual - part 145

 

 

anti-theft code.

– Disconnect the battery ground cable with the ignition switched

off. Refer to ⇒  Electrical Equipment; Rep. Gr.  27 ; Battery;

Battery, Disconnecting and Connecting .

– Remove the complete air filter housing if it is located above

Injection System; Air Filter Housing, Removing and Installing

Installing .

– Remove the shift cable lock washer -arrow 1- from the gear‐

shift lever -A-.

– Remove the shift cable from the pins.
Metal Relay Lever
– Remove the selector cable circlip -2- from the relay lever -B-.
– Remove the selector cable from the pins.
– Remove the lock washer -arrow 3- from the relay lever -B- and

then remove the relay lever.

Plastic Relay Lever
– Remove the relay lever together with the cable retainer from

the transmission. Refer to

⇒ “1.8 Plastic Relay Lever”, page 77

 .

Continuation for All

– Remove the nut -arrow 4- and then remove the transmission

shift lever -A-.

– Remove the cable bracket from the transmission -arrows-.
– Tie up the shift cable and the selector cable.
– Remove the bracket -B- from the transmission and pull it off

the hose/line assembly -A-.

42

the clutch slave cylinder.

– Remove the hose/line assembly from the clutch slave cylinder

and seal it.

– Remove the clutch slave cylinder -B arrows-.

Caution

Do not press the clutch pedal anymore.

1.10.2

Installing

Install in reverse order of removal while. Note the following:
– Install the clutch slave cylinder and tighten the bolts

-arrows B- to the tightening specification.

– Attach the hose/line assembly to the clutch slave cylinder.
– Push in the clamp for the hose/line assembly until it stops.
– Pull on the hose/line assembly to make sure it is secure.
– Install the transmission support -arrows A-.
– Bleed the clutch system after installing the clutch slave cylin‐

der. Refer to 

⇒ “1.11 Clutch System, Bleeding”, page 44

 .

Assemble the gearshift mechanism. Refer to

⇒ “1.7 Overview - Operating Cables, Removing and Installing”,

page 73

 .

Adjust the gearshift mechanism. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 85

 .

23 ; Diesel Direct Injection System; Air Filter Housing, Re‐

Housing, Removing and Installing .

– Connect the battery ground cable. Refer to ⇒  Electrical Equip‐

ment; Rep. Gr.  27 ; Battery; Battery, Disconnecting and

Connecting .

1.10.3

Tightening Specifications

Clutch slave cylinder on the transmission. Refer to -item 9-

⇒ Item 9 (page 46)

 .

Transmission selector lever to selector shaft -item 18-

⇒ Item 18 (page 76)

 .

Cable mounting bracket to transmission. Refer to -item 6-

⇒ Item 6 (page 74)

 .

1. Clutch Mechanism, Servicing    

43

Bolts -arrows-

20 Nm +90°

1.11

Clutch System, Bleeding

Special tools and workshop equipment required
♦ Brake Charger/Bleeder Unit - VAS5234- or
♦ Brake Charger/Bleeder Unit - VAG1869-

Note

It is not necessary to pre-fill the system.

Hydraulic System .
Perform the following procedure:
– Remove the air filter housing if the breather valve -arrow- is

Gr.  24 ; Air Filter; Air Filter Housing, Removing and Installing .

– Connect the Brake Charger/Bleeder Unit - VAS5234- or -

VAG1869- .

It is necessary to use the Bleeder Hose (670 mm) - VAG1238/B3-

to bleed.
– Connect the bleed hose to the brake bleeder unit collector

bottle.

– Attach the bleed hose to the breather valve -arrow-.
– Apply 2 bar pressure to the system.
– Open the breather valve.
– Let approximately 100 cm

3

 of brake fluid flow out.

– Close the breather valve.
– Operate the pedal rapidly from stop to stop, 10 to 15 times.
– Open the breather valve again.
– Let another 50 cm

3

 of brake fluid flow out.

23 ; Diesel Direct Injection System; Air Filter Housing, Re‐

Housing, Removing and Installing .

44

Clutch Release Mechanism, Servic‐

ing

Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Grease for Clutch Disc Shaft Splines - G 000 100-

1 - Transmission
2 - Ball Stud

❑ 25 Nm
❑ For removing and instal‐

ling, remove the trans‐

mission

❑ remove grease from ex‐

tractor lever contact sur‐

faces

❑ Grease using the

Grease for Clutch Disc

Shaft Splines - G 000

100-

3 - Input Shaft Seal

❑ For removing and instal‐

ling, remove the trans‐

mission

❑ Replacing. Refer to

⇒ Item 12 (page 185)

 .

4 - Guide Sleeve

❑ For removing and instal‐

ling, remove the trans‐

mission

❑ With vulcanized O-ring
❑ Replace the guide

sleeve and O-ring to‐

gether if the O-ring is

damaged.

5 - Spring

❑ For removing and instal‐

ling, remove the trans‐

mission

❑ Attach to the clutch re‐

lease lever

6 - Cylinder Bolt

❑ 20 Nm

7 - Clutch Release Lever

❑ For removing and installing, remove the transmission
❑ Remove and install together with release bearing. Refer to

⇒ Fig. ““Removing and Installing the Release Bearing”“ , page 46

❑ remove grease already present

8 - Release Bearing

❑ For removing and installing, remove the transmission
❑ Do not wash the bearing, just wipe it off.
❑ Replace loud bearings

2. Clutch Release Mechanism, Servicing    

45

 

 

 

 

 

 

 

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