Volkswagen Golf Variant / Jetta. Manual - part 519

 

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

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  517  518  519  520   ..

 

 

Volkswagen Golf Variant / Jetta. Manual - part 519

 

 

tightening specification -item 9- 

⇒ Item 9 (page 44)

 .

– Press line between clutch master and slave cylinder -A- into

bracket -B-, if present, on transmission.

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

G266- .

– Attach the cable mounting bracket to the transmission and

tighten the bolts -arrows- to the tightening specification

-item 6- 

⇒ Item 6 (page 67)

 .

92

⇒ Fig. ““Installing the transmission shift lever”“ , page 69

 ) and

tighten the nut -arrow 4- -item 17- 

⇒ Item 17 (page 68)

 .

Metal Relay Lever

Note

Lubricate the bearing areas and sliding surfaces when instal‐

ling.

Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.

– Place the relay lever -B- into the bearing on the gearshift cover.
– Tilt relay lever so that it engages with the slide shoe in the

guide on the transmission shift lever.

– Secure relay lever with new lock washer -arrow 3-.
Plastic Relay Lever
– Install the relay lever together with the cable retainer. Refer to

⇒ “1.11 Plastic Relay Lever”, page 78

 .

Continuation for All
– Coat the pin on the gearshift lever with a small amount of

grease -A-.

– Attach the shift cable to the gearshift lever -arrow 1- and install

a new locking washer.

– Adjust the gearshift mechanism. Refer to

⇒ “1.10 Selector Mechanism, Adjusting”, page 76

 .

– Check the transmission fluid level. Refer to

⇒ “5 Transmission Fluid, Checking”, page 111

 .

If the transmission touched any other components, then repair

any damaged surfaces. Refer to Paint Repair Manual.
– Install the lower part of the left front wheel housing liner. Refer

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

50 ; Noise Insulation .

– Install the engine cover and the air filter housing. Refer to ⇒ 

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

stalling .

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

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

moving and Installing .

– Connect the battery and follow the procedure regarding what

to do after connecting a battery. Refer to ⇒  Electrical Equip‐

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

Connecting .

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

93

Tightening Specifications

Transmission To Engine
Vehicles with 1.4 engine

Item

Bolt

Quantity

Nm

1

M 12 x 65

2

80

2

M 12 x 135

♦ Also starter to

transmission

1

80

3

M 12 x 150

♦ Also starter to

transmission

1

80

4

M 12 x 80

1

80

5

M 10 x 35

2

40

-5-: cover plate to transmission

-A- alignment sleeves for centering

Transmission Support to Transmission
– Replace the bolts.

Bolts -arrows-

40 Nm +90°

Transmission Support to Transmission Mount
– Replace the bolts.

Bolts -arrows-

60 Nm +90°

Component

Nm

Bracket for lower starter plug wires

20

Ground cable to engine/transmission bolt

20

94

Transmission, Removing and Instal‐

ling, Jetta from MY 2011

⇒ “3.1 Transmission Removing, Jetta 2011 with 2.0L engine”,

page 95

 .

⇒ “3.2 Transmission, Installing, Jetta 2011 with 2.0L Engine”,

page 102

 .

⇒ “3.3 Tightening Specifications”, page 108

 .

3.1

Transmission Removing, Jetta 2011

with 2.0L engine

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

the Mounting Plate on the Transmission Support )

♦ Engine and Gearbox Jack - VAS6931-
♦ Tensioning Strap - T10038-
♦ Engine Support - Basic Set - T40091-
♦ Engine Support - Supplement Kit - T40093A-
♦ Transmission Support - Mounting Plate 31 - 3282/31-
♦ Transmission Support - Pins 45 - 3282/45-
♦ Socket - Xzn 14 - T10061-
♦ Grease for Clutch Disc Shaft Splines - G 000 100-
♦ Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.

– Determine whether a coded radio is installed. If so, obtain the

anti-theft code.

Disconnect the battery ground cable. Refer to ⇒  Electrical Equip‐

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

Filter; Air Filter Housing, Removing and Installing .

– Remove the battery and the battery tray. Refer to ⇒  Electrical

Equipment; Rep. Gr.  27 ; Battery; Battery, Removing and In‐

stalling .

– Remove the shift cable lock washer -arrow 1- from the selector

lever -B-.

– Remove the shift cable from the pins.
– Remove the cable retainer from the selector cable. Refer to

⇒ Fig. ““Disconnecting the Cable Retainer from the Selector

Cable”“ , page 71

 .

– Remove the relay lever -A- and the cable retainer. Refer to

⇒ “1.11 Plastic Relay Lever”, page 78

 .

– Remove the nut -arrow 2- and remove the transmission shift

lever -B-.

3. Transmission, Removing and Installing, Jetta from MY 2011    

95

 

 

 

 

 

 

 

Content   ..  517  518  519  520   ..