Volkswagen Golf Variant / Jetta. Manual - part 237

 

  Index      Volkswagen     Volkswagen Golf Variant (2007), Jetta (2005) - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  235  236  237  238   ..

 

 

Volkswagen Golf Variant / Jetta. Manual - part 237

 

 

tighten the bolts and nuts -arrows- to the tightening specifica‐

tion -item 6- 

⇒ Item 6 (page 86)

 and -item 10-

⇒ Item 10 (page 86)

 .

– Apply a small amount of grease to the pin -arrow- on the gear‐

shift lever -1-.

Refer to the Parts Catalog for the grease allocation.
– Slide the shift cable onto the respective pins -arrow- and se‐

cure it with a new lock washer -3-.

Metal Relay Lever
– Apply a small amount of grease to the pin -arrow- of the relay

lever -2-.

Refer to the Parts Catalog for the grease allocation.
– Slide the selector cable onto the respective pins -arrow- and

secure it with a new lock washer -4-.

Plastic Relay Lever
– Insert the selector cable into the cable retainer.
Continuation for All
– Adjust the gearshift mechanism. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97

 .

– Install the battery tray, battery cover and the battery. Refer to

⇒  Electrical Equipment; Rep. Gr.  27 ; Battery; Battery, Re‐

moving and Installing .

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

Removing and Installing .

– Install the engine cover if necessary.
– Connect the battery and observe procedure after connecting

Battery, Disconnecting and Connecting .

– Check the transmission fluid level. Refer to

⇒ “8 Transmission Fluid, Checking”, page 192

 .

– Install the lower part of the left front wheel housing liner. Refer

to ⇒  Body Exterior; Rep. Gr.  66 ; Wheel Housing Liner .

50 ; Noise Insulation .

– Check the headlamp adjustment if the vehicle has a Left Front

Level Control System Sensor - G78- . Refer to ⇒  Electrical

2. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehicles with

Diesel Engine and FWD    

123

Tightening Specifications

Transmission to Engine (Engine Flange Face)

Item

Bolt

Quantity

Nm

1

M12 x 55

♦ With a short M8 threa‐

ded pin

1

80

2

M12 x 55

♦ With a long threaded

pin M8

1

80

3

M12 x 65

1

80

4

M10 x 50

2

40

5

M10 x 105

1

40

6

M12 x 165

♦ With a short M8 threa‐

ded pin

♦ Also starter to trans‐

mission

1

80

7

M12 x 165

♦ With a short M8 threa‐

ded pin

♦ Also starter to trans‐

mission

1

80

-

M6 x 8

♦ Small flywheel cover

plate (not present on all

engines)

1

10

-A- and -B-: alignment bushings

Transmission Bracket -1- to Transmission.
– Replace the bolts.
Tighten the bolts -arrows-: 60 Nm + 90°.

124

Note

Install the engine/transmission mount free of tension. Refer to ⇒ 

Rep. Gr.  10 ; Engine, Removing and Installing .

2. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehicles with

Diesel Engine and FWD    

125

Transmission, Removing and Instal‐

ling, Jetta from MY 2005 , Golf Wag‐

on from MY 2007 and Golf Wagon

from MY 2010, Vehicles with Gaso‐

line Engine and FWD

⇒ “3.1 Transmission, Removing and Installing”, page 126

 .

⇒ “6 Transmission, Transporting”, page 189

 .

⇒ “3.2 Tightening Specifications”, page 143

 .

3.1

Transmission, Removing and Installing

Special tools and workshop equipment required
♦ Engine Support Bridge - 10-222A-
♦ Engine Support Bridge - Engine Support Feet - 10-222A/8-
♦ Engine Support Bridge - Engine Support 3 - 10-222A /3-
♦ Engine Support Bridge - Engine Support 18 - 10-222A /18-
♦ Transmission Support - 3282-
♦ Support Elements for transmission (determine when mounting

the Mounting Plate on the Transmission Support )

♦ Transmission Support - Mounting Plate 33 - 3282/33-
♦ Transmission Support Jig - 3336- to transport the transmis‐

sion.

♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
♦ Engine and Gearbox Jack - VAS6931-
♦ Engine Support Bridge - Gearbox Bracket - T10346- quantity:

2

♦ Engine Support Device - 3300A-
♦ Slide Hammer Set - Adapter 40 - VW771/40-
♦ Hose Clamps - Up To 25mm - 3094-
♦ Grease for Clutch Disc Shaft Splines - G 000 100-
♦ Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.

♦ M6 x 20 collar bolt
♦ M6 x 80 collar bolt
♦ M10 x 20 hex bolt
Removing
The Engine Support Bridge - 10-222A- and the Engine Support

Bridge - Engine Support Feet - 10-222A/8- will be mounted on the

longitudinal members later in the procedure.

126

 

 

 

 

 

 

 

Content   ..  235  236  237  238   ..