Volkswagen Golf / Golf GTI / Jetta. Manual — part 259

00-10

Gaskets, sealing rings

Locking devices

Before installing oil seal, fill

space between sealing lips with
grease G 052 128 A1 -arrows-.

After installing, check oil level

Page 34-54

.

Thoroughly clean joint surfaces

and apply sealant AMV 188 200
03.

Apply sealant uniformly but not

too thick.

Replace "O-rings".

Replace circlips.

Do not overstretch circlips.

Circlips must locate properly in

the groove.

Replace spring pins installation

position: Slot longitudinal to line
of force.

General repair instructions

00-11

Bolts and nuts

Tighten and loosen bolts and nuts for securing

covers and housings in a diagonal sequence.

Especially delicate parts, such as clutch

pressure plates, must not be distorted. Loosen
and tighten nuts and bolts in stages in a
diagonal sequence.

Tightening torques as specified are for unoiled

bolts and nuts.

Replace self-locking bolts and nuts.

Make sure that on bolted connections the areas

around the contact surfaces as well as the
visible surfaces of nuts and bolts are rewaxed
after assembly, if necessary.

Bearings

Install new tapered roller bearings as supplied

and do not lubricate additionally.

Install needle bearings with lettered side

(thicker metal) towards fitting tool.

Tapered roller bearings fitted to one shaft must

be replaced as a set. Use the same make of
bearings.

Heat inner races to approx. 100 C before

installing.

Do not interchange outer or inner races of

bearings of the same size. The bearings are
matched in pairs.

General repair instructions

00-12

Shims

Measure shims at several points with a

micrometer. Tolerance variations make it
possible to find the exact shim thickness
required.

Check for burrs and damage.

Only install perfect shims.

Synchronizer rings

Do not interchange. When reusing always fit to

the same gear.

Check for wear and replace if necessary.

Coat with gear oil before installing.

Selector gears

Before installing clean and heat on a hot plate

to approx. 100 C.

Temperature can be checked with temperature

tester V.A.G 1558.

General repair instructions

30-1

Clutch
mechanism,
repairing

Note:

I -

Assembly
overview-
pedal

Page 30-2

II -

Assembly
overview-
hydraulics

Page

30-10

Disconnect

the battery
ground
strap.

For

vehicles
with a
coded
radio,
obtainthe
radio
code.

Lubricate

all
bearings
and
contact
surfaces
with poly
resin
grease
Part No. G
000 450
02.

Clutch mechanism, repairing