Volkswagen Golf Variant / Jetta. Manual - part 164

 

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Volkswagen Golf Variant / Jetta. Manual - part 164

 

 

-item 18- 

⇒ Item 18 (page 76)

 .

• Grease the relay lever before installation,

⇒ “1.8 Plastic Relay Lever”, page 77

 .

• Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.

– Insert the relay lever together with the cable retainer and se‐

cure them with the clip -arrow 1-.

– Coat the pin on the gearshift lever with a small amount of

grease -A-.

– Install the shift cable on the gearshift lever -A- and secure it

with new lock washer -arrow 2-.

• The clip -arrow 1- secures the relay lever.
• Make sure the clips locks securely.

Note

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

⇒ “1.8 Plastic Relay Lever”, page 77

 .

– Connect the selector cable to the cable retainer.
– Adjust the gearshift mechanism. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 85

 .

– Install the plenum chamber cover. Refer to ⇒  Body Exterior;

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

Cover, Removing and Installing .

118

taining brackets to the tightening specification. Refer to ⇒ 

Body Exterior; Rep. Gr.  50 ; Lock Carrier; Lock Carrier - At‐

tachments .

Note

If when removing the flange shaft, the transmission fluid leaks out,

drain and fill the transmission fluid for the installed transmission

and flange shaft. Refer to

⇒ “6 Transmission Fluid, Checking and Filling”, page 157

 .

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

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

stalling .

Housing, Removing and Installing .

– Connect the battery and follow the procedure regarding what

to do after connecting a battery. Refer to ⇒  Electrical Equip‐

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

Connecting .

– Install the left front wheel housing liner. Refer to ⇒  Body Ex‐

ing Liner, Removing and Installing .

50 ; Noise Insulation .

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

Rep. Gr.  44 ; Wheel Installation Tightening Specifications .

3.2.1

Tightening Specifications

Transmission to engine

Item

Bolt

Quantity

Nm

1

M 12 x 65

2

80

2

M 12 x 150

♦ Also starter to

transmission

1

80

3

M 12 x 165

♦ Also starter to

transmission

1

80

4

M10 x 50

3

40

5

M 12 x 85

1

80

6

M6 x 8

♦ Small flywheel

cover plate

1

10

-A- alignment sleeves for centering

Component

Nm

Bracket for lower starter plug wires

20

Ground cable to engine/transmission bolt

20

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

119

Transmission, Removing, Jetta MY

2011, 2.5L 125 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 .

24 ; Air Filter; 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

 .

– Remove the clip -arrow 1- and then remove the relay lever and

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-.

120

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 .

So that engine and transmission can be supported:

– Remove the wires -1- from the transport strap -3-.
– Remove the transport strap -3- from the engine -2- and pull it

out of the eye -arrow-.

– Insert a Engine/Gearbox Support Shackle (2 pc.) - 10 - 222 A /

12- in »this« eye.

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

121

 

 

 

 

 

 

 

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