Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 481

Cautions & Warnings

Page 3 of 3

© 2002 Volkswagen of America, Inc.

All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.

Version 1.0

•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the

battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.

•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained

Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.

•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been

inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.

•=

When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.

I have read and I understand these Cautions and Warnings.

Repair Manual

Golf 2015 ➤

Golf Variant 2015 ➤

Manual Transmission

Edition 02.2016

Service

Service Department. Technical Information

List of Workshop Manual Repair Groups

Repair Group

00 - General, Technical Data
30 - Clutch
34 - Controls, Housing
35 - Gears, Shafts
39 - Final Drive, Differential

Technical information should always be available to the foremen and mechanics, because their

careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and

safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a

matter of course, be observed.

Service

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2016 Volkswagen AG, Wolfsburg

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Contents

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1.1

Transmission Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

2.1

Road Test with Testing Equipment Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

2.2

Start/Stop System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

3

Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

3.1

General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

3.2

Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

4

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

4.1

Transmission/Engine Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

4.2

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

4.3

Gear Ratio Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

5

Overview - Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

5.1

Overview - Powertrain, Front Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

6

Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6.1

Overview - Electrical Components Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1

Clutch Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.1

Overview - Component Location, Clutch Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2

Overview - Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.3

Overview - Clutch Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.4

Overview - Clutch Release Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.5

Over-Center Spring, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.6

Return Spring, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.7

Clutch Pedal, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.8

Mounting Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.9

Bearing Bushing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.10 Clutch Master Cylinder, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.11 Clutch Slave Cylinder with Release Bearing, Removing and Installing . . . . . . . . . . . . . . . . 33

1.12 Clutch Mechanism Lines, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.13 Bleeder, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1.14 Clutch Master and Clutch Slave Cylinder, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1.15 Clutch Position Sensor G476 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 37

1.16 Clutch Mechanism, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

1.17 Clutch Release Mechanism, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.1

Clutch Manufacturers, Differentiating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.2

Overview - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2.3

Clutch, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

1

Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

1.1

Selector Mechanism Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

1.2

Overview - Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

1.3

Overview - Shift Lever Knob and Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

1.4

Gearshift Knob, Removing and Installingg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

1.5

Selector Mechanism, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1.6

Selector Mechanism, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71