Volkswagen Golf Variant / Jetta. Manual - part 211

 

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Volkswagen Golf Variant / Jetta. Manual - part 211

 

 

ings diagonally with a tightening sequence.

♦ Especially delicate components, such as clutch pressure

plates, must not be distorted. Loosen and tighten bolts and

nuts in stages in a diagonal sequence.

♦ The tightening specifications given apply to unoiled bolts and

nuts.

♦ Always replace self-locking bolts and nuts.
♦ Make sure the contact surfaces and visible surfaces on the

nuts and bolts are waxed after assembling.

♦ Use a wire brush to clean the threads of the bolts that were

installed with locking fluid. Then insert the bolts with Locking

Fluid - AMV 185 101 A1- .

♦ Clean the threaded holes for the self-locking bolts or for the

bolts coated with locking fluid (for example with a thread tap).

Otherwise the bolts could shear the next time they are re‐

moved.

♦ Please make sure that the thread pitch is correct so that the

proper thread tap is used during cleaning, and the thread does

not get damaged.

♦ Make sure the contact surfaces and visible surfaces on the

nuts and bolts are waxed after assembling.

Bearings
♦ Install needle bearings with the lettered side (thicker metal)

facing the fitting tool.

♦ Insert all the bearings in transmission with transmission fluid.
♦ Replace all the tapered roller bearings that are on the same

shaft, and use tapered roller bearings from the same manu‐

facturer.

♦ Heat the tapered roller bearing inner races to approximately

100 °C (212 °F) with the Inductive Heat Unit - VAS6414- before

installing. Press on to the stop when installing, so there is no

axial clearance.

♦ Do not interchange outer and inner bearing races with those

from other bearing of the same size. The bearings are paired.

Shims
♦ Measure the shims at several locations with a micrometer cal‐

iper. Tolerance variations make it possible to find the exact

shim thickness required.

♦ Check for scratches and damages.
♦ Only install flawless shims.
Synchronizer Rings

7. General Repair Information    

19

always install on the same gear wheel.

♦ Check for wear and replace if necessary.
♦ Check the grooves -arrow 1- on the synchronizer ring -A- and

the inner race for flat areas (grooves are worn).

♦ The coating on the synchronizer rings must not be damaged.
♦ If an intermediate ring -B- is installed, check the outer friction

surface -arrow 2- and the inner friction surface -arrow 3- for

»grooves« and »scoring«.

♦ Check taper of drive gear for »grooves« and »scoring«.
♦ Coat the synchronizing ring with transmission fluid and then

install.

Gear Wheels, Synchronizer Hubs and Needle Bearing Sleeve
♦ Warm the needle bearing sleeves to approximately 100 °C

(212 °F) with an Inductive Heater - VAS6414- .

♦ Heat the synchronizer hub to approximately 100 °C (212 °F)

with the Inductive Heat Unit - VAS6414- before installing.

Press on as far as the stop when installing so there is no axial

play.

♦ Heat the gears to approximately 100 °C (212 °F) with the In‐

ductive Heat Unit - VAS6414- before installing. Press on as far

as the stop when installing so there is no axial play.

♦ Pay attention to the installed location.
Selector Gears
♦ After assembling, check the selector gears for minimum axial

clearance and ease of movement.

Clutch
♦ Do not tilt the clutch pressure plate. Loosen and tighten it di‐

agonally and in small steps.

♦ To reduce odor caused by a burnt clutch, thoroughly clean the

clutch housing and the flywheel running surface with a clean

cloth.

20

1

Clutch Mechanism, Servicing

⇒ “1.1 Overview”, page 21
⇒ “1.2 Overview - Pedal Cluster”, page 23
⇒ “1.3 Over-Center Spring, Removing and Installing”, page 24
⇒ “1.4 Clutch Pedal, Removing and Installing”, page 29
⇒ “1.5 Mounting Bracket, Removing and Installing”, page 35
⇒ “1.6 Clutch Master Cylinder, Removing and Installing”,

page 40
⇒ “1.7  Clutch Position Sensor G476 , Removing and Installing”,

page 41
⇒ “1.8 Overview - Hydraulics”, page 43
⇒ “1.10 Clutch Mechanism, Bleeding”, page 48

1.1

Overview

Note

Get the anti-theft code for the radio before disconnecting the battery.

Disconnect the battery ground cable. Refer to ⇒  Electrical Equipment; Rep. Gr.  27 ; Battery; Battery,

Disconnecting and Connecting .

necting the battery.

Lubricate all bearing areas and contact surfaces.

Refer to the Parts Catalog for the grease allocation.

1. Clutch Mechanism, Servicing    

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