Volkswagen Golf Variant / Jetta. Manual - part 230

 

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Volkswagen Golf Variant / Jetta. Manual - part 230

 

 

mission as follows:

• The cables must run parallel to each other and must not cross

each other.

• The cables must be routed inside the depression in the heat

shield -3-.

Note

The heat shield from above is shown in the magnified view.

A clip -A- holds the cables and heat shield to each other in place.
These holes have different diameters.
Cable retainer allocation. Refer to

⇒ Fig. ““Cable Retainer Allocation”“ , page 87

– Apply a small amount of grease on the pins on the transmis‐

sion shift lever -arrows- -1- and on the relay lever -2-.

• Refer to the Parts Catalog for the grease allocation.
– Replace the lock washer -3- and the lock washer -4- on the

metal relay lever each time they are removed.

– Secure shift cable with lock washer -3- and selector cable with

lock washer -4-.

Cable Retainer with Plastic Relay Lever
– The relay lever and cable retainer must be installed together.

Refer to 

⇒ “1.8 Plastic Relay Lever”, page 89

 .

– Insert the selector cable into the cable retainer.
Continuation for All Shift Mechanisms
– Install the bracket and the center console. Refer to ⇒  Body

Interior; Rep. Gr.  68 ; Center Console .

– Install the boot with the shifter knob and noise insulation. Refer

to

⇒ “1.4 Boot with Shifter Knob and Noise Insulation, Removing

and Installing”, page 79

 .

1. Shift Mechanism, Servicing    

95

attach with the lock washers -2 and 3-.

– Attach the underbody trim panel to the body -arrows-. Refer to

⇒  Body Exterior; Rep. Gr.  50 ; Underbody Trim Panels .

AWD Vehicles
– Install the driveshaft. Refer to ⇒  Rear Final Drive; Rep. Gr. 

39 .

Continuation for All
– Install the exhaust system and align it without tension. Refer

– Install the tunnel braces under the exhaust system. Refer to

⇒  Body Exterior; Rep. Gr.  50 ; Tunnel Brace .

– Adjust the gearshift mechanism. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97

 .

– If it was removed earlier install the complete air filter housing.

Filter; Air Filter Housing, Removing and Installing .

– Complete the steps after connecting the battery. Refer to ⇒ 

Electrical Equipment; Rep. Gr.  27 ; Battery; Battery, Discon‐

necting and Connecting .

1.10

Gearshift Cable and Selector Cable, Re‐

moving and Installing

Removing
– Remove the selector mechanism. Refer to 

⇒ page 93

 .

– Bend up the tabs -arrows- on the shift mechanism base plate

using a screwdriver and remove the base plate. Only the

straps on the left side of the base plate are shown in the illus‐

tration.

– Remove the seal.

– Remove the lock washers -1 through 4-.

Note

Lock washers -1 and 4- are no longer installed in shift mecha‐

nisms beginning in 11/2006.

– Pry off the shift cable (or the selector lever cable) from the

gearshift lever (or selector lever) with a screwdriver.

– Remove the shift cable and selector cable from the shift hous‐

ing.

96

follows:
♦ Push the sleeve forward as far as it will go in direction of

-arrow 1-.

♦ Turn the sleeve to the right as far as it will go in direction of

-arrow 2- until it engages.

– Remove the retainers from the cables.

– Remove the lock washers -1 and 2-.
– Remove the cable bracket from the cables.
Installing
Install in reverse order of removal while. Note the following:

– Secure the shift cable and selector cable on the shift housing

with lock washers -2 and 3-.

– Attach the shift cable and the selector cable to the gearshift

lever and the selector lever inside the shift housing and secure

it with lock washers -1 and 4-.

Note

Lock washers -1 and 4- are no longer installed in shift mecha‐

nisms beginning in 11/2006.

– Install the base plate with a new seal on the gearshift housing

-arrows-. Refer to

⇒ Fig. ““Base Plate, Attaching to Gearshift Housing”“ ,

page 105

 .

– Install the gearshift mechanism. Refer to 

⇒ page 94

 .

– Adjust the gearshift mechanism. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97

 .

1.11

Selector Mechanism, Adjusting

Connecting Pin - T10027A-

1. Shift Mechanism, Servicing    

97

The following is important to make sure the gearshift adjust‐

ment is correct:

Operating and transfer elements of shift mechanism must be

in proper condition.

Shift mechanism must move freely.

The transmission, clutch and clutch mechanism must also be

in proper condition.

• Transmission in neutral.
– Remove the entire air filter housing if the bracket -A- for the

selector shaft and the securing mechanism for the shift and

Gr.  23 ; Diesel Direct Injection System; Air Filter Housing,

Housing, Removing and Installing .

– Pull the safety mechanism on the cable retainer for the shift

cable and the selector cable all the way forward in direction of

-arrow 1- and then lock it to the left in direction of -arrow 2-.

Hold the gearshift shaft secure as follows:
– Push the gearshift shaft in direction of -arrow 1-.
– While pressing down selector shaft, rotate lock bolt -A- upward

in direction of -arrow 3- and simultaneously press it in direction

of -arrow 2- until it engages in selector shaft.

– Remove the boot with the shifter knob and frame. Refer to

⇒ “1.4 Boot with Shifter Knob and Noise Insulation, Removing

and Installing”, page 79

 .

– If equipped, remove the noise insulation.

98

 

 

 

 

 

 

 

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