Volkswagen Golf Variant / Jetta. Manual - part 241

 

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

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  239  240  241  242   ..

 

 

Volkswagen Golf Variant / Jetta. Manual - part 241

 

 

sion -arrows- and tighten them to the tightening specification.

Refer to 

⇒ “3.2 Tightening Specifications”, page 143

 .

– Align the engine/transmission in its installed position. Lift it un‐

til the bracket -1- is in complete contact with the left subframe

mount -2-.

– Install the new hex bolts -arrows- of the left subframe mount

-2- in the bracket -1- and tighten to the tightening position.

Refer to 

⇒ “3.2 Tightening Specifications”, page 143

 .

Note

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

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

WARNING

Only remove the Engine Support Bridge - 10-222A- when all

subframe mount bolts are tightened to the tightening specifi‐

cation.

– Install the flywheel cover plate -A- (if equipped) -arrows-. Refer

to 

⇒ “3.2 Tightening Specifications”, page 143

 .

Note

There are threaded inserts (for example “Heli Coil”) in the pen‐

dulum support fastening holes.

How to recognize: there is a collar on the first thread -arrow-.

Observe the correct bolts and tightening specifications. Refer

Overview - Subframe .

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

Gasoline Engine and FWD    

139

Steering; Rep. Gr.  40 ; Subframe; Overview - Subframe .

ing; Rep. Gr.  40 ; Drive Axles, Removing and Installing .

– If equipped install the drive axle heat shield -arrows-. Refer to

⇒  Suspension, Wheels, Steering; Rep. Gr.  40 ; Drive Axles,

Overview and Servicing; Drive Axle Heat Shield .

– Install the left coupling rod. Refer to ⇒  Suspension, Wheels,

Steering; Rep. Gr.  40 .

– Install the Left Front Level Control System Sensor - G78- in

– Connect the connector -1- to the Oil Level Thermal Sensor -

G266- .

140

Rep. Gr.  19

– Install the charge air hoses -arrow 1 and arrow 2- and then

21 .

– Position the starter and install the lower bolt. Refer to ⇒  Elec‐

Installing .

– Attach the bracket for the lines to the lower starter bolt.
– Install the starter bolt and then connect the connector and

27 ; Starter; Starter, Removing and Installing .

– Attach the ground cable -1- to the top starter bolt.
– Connect the connector -2- to the Back-Up Lamp Switch - F4- .

– Push the hose/line assembly or pipe -A- into the bleeder/clutch

slave cylinder to the stop and push the clamp -arrow- down‐

ward.

– Pull on the line to make sure it is secure.
– Remove the Hose Clamp - 3094- from the supply hose.
– After removing the Hose Clamps - Up To 25mm - 3094- , bring

the return hose back to its original shape.

– Bleed the clutch mechanism. Refer to

⇒ “1.10 Clutch Mechanism, Bleeding”, page 48

 .

– Make sure the vacuum hose for the brake system is installed

correctly. Refer to ⇒  Brake System; Rep. Gr.  47 ; Hydraulic

System .

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

Gasoline Engine and FWD    

141

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 .

– Install the air filter housing, if it was removed earlier. Refer to

Installing .

– Install the plenum chamber cover and seal. Refer to ⇒  Body

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

Chamber Cover, Removing and Installing .

– Attach the foam pieces to the upper edges on the left and right

fenders. Refer to ⇒  Body Exterior; Rep. Gr.  50 ; Fender .

– 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

142

 

 

 

 

 

 

 

Content   ..  239  240  241  242   ..