Volkswagen Golf Variant / Jetta. Manual - part 506

 

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Volkswagen Golf Variant / Jetta. Manual - part 506

 

 

shift lever -A-.

– Remove the shift cable from the pins.
Metal Relay Lever
– Remove the selector cable circlip -2- from the relay lever -B-.
– Remove the selector cable from the pins.
– Remove the lock washer -arrow 3- from the relay lever -B- and

then remove the relay lever.

Plastic Relay Lever
– Remove the relay lever together with the cable retainer from

the transmission. Refer to

⇒ “1.11 Plastic Relay Lever”, page 78

 .

Continuation for All
– Remove the nut -arrow 4- and then remove the transmission

shift lever -A-.

– Remove the cable bracket from the transmission -arrows-.
– Tie up the shift cable and the selector cable.
– Place a lint-free cloth under the clutch slave cylinder.

– Pull clip -A- for line between clutch master and slave cylinder

out of the clutch slave cylinder as far as stop.

– Pull line between clutch master and slave cylinder out of mount

-C-.

– Pull line connection -B- out of clutch slave cylinder and seal

opening.

– Remove the clutch slave cylinder -arrows-.

Caution

Do not press the clutch pedal anymore.

2.10.2

Installing

Install in reverse order of removal while. Note the following:

40

to the tightening specification -item 9- 

⇒ Item 9 (page 44)

 .

– Insert the line -B- between clutch master and slave cylinder in

the clutch slave cylinder as far as stop.

– Install the clip -A- for securing the line between the clutch

master and slave cylinder as far as stop.

– Pull on the line to make sure it is secure.
– Install the line between the clutch master and slave cylinder

all the way into the mount -C- on transmission.

– Bleed the clutch mechanism after installing the clutch slave

cylinder. Refer to

⇒ “3 Clutch Mechanism, Bleeding”, page 42

 .

– Assemble the gearshift mechanism. Refer to

⇒ “1.8 Selector Mechanism, Removing and Installing”,

page 70

 .

Adjust the gearshift mechanism. Refer to

⇒ “1.10 Selector Mechanism, Adjusting”, page 76

 .

– If removed, install the complete air filter housing. Refer to ⇒ 

Rep. Gr.  24 ; Air Filter; Air Filter Housing, Removing and In‐

stalling .

– Connect the battery ground cable. Refer to ⇒  Electrical Equip‐

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

Connecting .

2. Clutch Mechanism, Servicing    

41

Clutch Mechanism, Bleeding

Special tools and workshop equipment required
♦ Brake Charger/Bleeder Unit - VAS5234- or
♦ Brake Charger/Bleeder Unit - VAG1869-

Note

It is not necessary to pre-fill the system.

Hydraulic System .
– Remove the air filter housing if the breather valve -arrow- is

Housing, Removing and Installing .

– Connect the Brake Charger/Bleeder Unit - VAS5234- or -

VAG1869- .

It is necessary to use the Bleeder Hose (670 mm) - VAG1238/B3-

to bleed.
– Connect the bleed hose to the brake bleeder unit collector

bottle.

– Attach the bleed hose to the breather valve -arrow-.
– Apply 2 bar pressure to the system.
– Open the breather valve.
– Let approximately 100 cm

3

 of brake fluid flow out.

– Close the breather valve.
– Operate the pedal rapidly from stop to stop, 10 to 15 times.
– Open the breather valve again.
– Let another 50 cm

3

 of brake fluid flow out.

– Close the breather valve.
– Press the clutch pedal a few times after bleeding the system.
– If removed, install the complete air filter housing. Refer to ⇒ 

Rep. Gr.  24 ; Air Filter; Air Filter Housing, Removing and In‐

stalling .

42

Clutch Release Mechanism, Servic‐

ing

⇒ “4.1 Overview - Clutch Release Mechanism”, page 43
⇒ “4.2 Clutch Release Lever with Release Bearing and Guide

Sleeve, Removing and Installing”, page 44

4.1

Overview - Clutch Release Mechanism

1 - Release Bearing

❑ Remove and install to‐

gether with the clutch re‐

lease lever -item 3-

⇒ Item 3 (page 43)

and guide sleeve

-item 5-

⇒ Item 5 (page 43)

❑ Removing and instal‐

ling. Refer to

⇒ “4.2 Clutch Release

Lever with Release

Bearing and Guide

Sleeve, Removing and

Installing”, page 44

 .

❑ Do not wash the bear‐

ing, just wipe it off.

❑ Replace loud bearings

2 - Bolt

❑ 5 Nm and 90° additional

turn

❑ Replace after removing

3 - Clutch Release Lever

❑ Remove and install to‐

gether with the release

bearing -item 1-

⇒ Item 1 (page 43)

 and

guide sleeve -item 5-

⇒ Item 5 (page 43)

❑ Removing and instal‐

ling. Refer to

⇒ “4.2 Clutch Release

Lever with Release

Bearing and Guide

Sleeve, Removing and

Installing”, page 44

 .

❑ remove grease already present

4 - Spring

❑ Attach to the clutch release lever

5 - Guide Sleeve

❑ Remove and install together with the release bearing -item 1- 

⇒ Item 1 (page 43)

 and clutch release lever

-item 3- 

⇒ Item 3 (page 43)

❑ Removing and installing. Refer to

⇒ “4.2 Clutch Release Lever with Release Bearing and Guide Sleeve, Removing and Installing”,

page 44

 .

6 - Input Shaft Seal

❑ Pry out with a screwdriver
❑ Installing. Refer to 

⇒ Fig. ““Installing the Seal for the Input Shaft”“ , page 129

4. Clutch Release Mechanism, Servicing    

43

 

 

 

 

 

 

 

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