Volkswagen Golf Variant / Jetta. Manual - part 160

 

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Volkswagen Golf Variant / Jetta. Manual - part 160

 

 

Transmission, Removing and Instal‐

ling, Jetta from MY 2011

⇒ “3.1 Transmission, Removing, Jetta MY 2011, 2.0L 85 kW”,

page 102
⇒ “3.2 Transmission, Installing, Jetta MY 2011 with 2.0L 85 kW

Engine”, page 111
⇒ “3.3 Transmission, Removing, Jetta MY 2011, 2.5L 125 kW”,

page 120
⇒ “3.4 Transmission, Installing, Jetta MY 2011, 2.5L 125 kW”,

page 130
⇒ “3.5 Transmission, Removing, Jetta 2011 with Turbo Diesel

Engine”, page 137
⇒ “3.6 Transmission, Installing, Jetta 2011 with Turbo Diesel En‐

gine”, page 146

3.1

Transmission, Removing, Jetta MY

2011, 2.0L 85 kW

Special tools and workshop equipment required
♦ Engine Support Bridge - 10 - 222 A-
♦ Transmission Support - 3282-
♦ Support Elements for transmission (determine when mounting

the Mounting Plate on the Transmission Support )

♦ Engine and Gearbox Jack - VAS6931-
♦ Tensioning Strap - T10038-
♦ Engine Support - Basic Set - T40091-
♦ Engine Support - Supplement Kit - T40093A-
♦ Spindle from the Seal Installer - Driver Set - 3066- or bolt M8

x 105

♦ Transmission Support - Pins 29 - 3282/29-
♦ Transmission Support - Mounting Plate 39 - 3282/39-
♦ Seal Installer - One-Piece Seal - T10148-
♦ Grease for Clutch Disc Shaft Splines - G 000 100-
♦ Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.

– Determine whether a coded radio is installed. If so, obtain the

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 .

Air Filter Housing, Removing and Installing .

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

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

stalling .

– Remove the cable retainer from the selector cable. Refer to

⇒ “1.8 Plastic Relay Lever”, page 77

 .

102

the cable retainer.

Note

The relay lever is secured by a notch on some vehicles. Refer to

⇒ “1.8 Plastic Relay Lever”, page 77

 .

– Remove the shift cable lock washer -arrow 2- from the selector

lever -A-.

– Remove the shift cable from the pins.
– Remove the nut -arrow 3- 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-.

– Remove the transmission support -arrows A-.
– Remove clutch slave cylinder -arrow B- and lay aside, secure

with wire, do not open line system.

Caution

The clutch slave cylinder could be damaged.

♦ If the clutch slave cylinder is removed from the transmis‐

sion with pipe/hose line still connected, do not press the

clutch pedal.

– Disconnect the connector -arrow 1- from the Back-Up Lamp

Switch - F4- .

– Remove the connector -arrow 2- and wire -arrow 3- from the

starter.

– Disconnect the ground cable from the upper engine/transmis‐

sion bolt.

– Remove the upper bolt from the starter.
– Remove the upper engine/transmission bolts.
– Remove the plenum chamber cover. Refer to ⇒  Body Exterior;

Rep. Gr.  50 ; Plenum Chamber Cover; Plenum Chamber

Cover, Removing and Installing .

3. Transmission, Removing and Installing, Jetta from MY 2011    

103

retaining brackets.

– Remove the lower mounts on the Engine Support Bridge - En‐

gine Support 28 - 10 - 222 A /28- and replace them with the

Engine Support Bridge - Engine Support 28-2 -10-222 A /

28-2- .

– Remove the bolts -arrows- for securing the engine support

bridge on the lock carrier from the Engine Support Bridge -

Engine Support 28-2 - 10-222 A /28-2- .

• Use the bolts in the Engine Support Bridge - Engine Support

28-2 -10 - 222 A /28-2- for attaching the Engine Support Bridge

- Engine Support 28 - 10 - 222 A /28- . Not the bolts for the

retaining bracket.

– Install the Engine Support Bridge - Engine Support 28 - 10 -

222 A /28- and tighten the bolts to 8 Nm -arrows-.

Caution

A second technician is required to mount the Engine Support

Bridge - 10 - 222 A- on the vehicle to prevent the Engine Sup‐

port Bridge from tipping.

– If there are hose and cable connections located near the en‐

gine lifting eyes for the Engine Support Bridge - 10 - 222 A- ,

these must now be removed.

104

assembly as follows:
1 - Engine Support Bridge - Engine Support 31 - Adapter 2 - 10

- 222 A /31-2-

2 - Engine Support - Basic Set - Moveable Joint - T40091/3-
3 - Engine Support Bridge - Engine Support 31 - Adapter 1 - 10

- 222 A /31-1-

4 - Engine Support - Supplement Kit - Movable Joint -

T40093/4-

5 - Engine Support - Basic Set - Square Pipe - T40091/1-
6 - Engine Support Bridge - Engine Support 28 - 10 - 222 A /

28- with Engine Support Bridge - Engine Support 28-2

-10-222 A /28-2-

– First slide the Moveable Joints -2- onto the Square Pipe from

the Engine Support Bridge - 10 - 222 A- .

• The bolts for the Movable Joints - T40091/3- -2- on the Engine

Support Bridge -10-222 A- face the direction of travel.

– Mount the Engine Support Bridge - 10 - 222 A- on the sus‐

pension strut towers and have a second technician hold it to

prevent it from tipping.

– Push the Engine Support - Basic Set - Square Pipe -T40091/1-

- 5- from the front left and right through the Engine Support

Bridge - Engine Support 28 -10 - 222 A /28- - 6- and place on

each side of the Engine Support - Supplement Kit - Movable

Joint - T40093/4- - 4-.

3. Transmission, Removing and Installing, Jetta from MY 2011    

105

 

 

 

 

 

 

 

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