Volkswagen Golf Variant, Jetta. Manual — part 27
led on “new” gearbox in some cases
⇒ page 114
.
Note
There is no need to renew oil seal for flange shaft when doing
this.
– Remove right-hand flange shaft of gearbox in order to install
gearbox.
Gearbox with flange shafts, torque setting
⇒ page 118
.
Bolt has a 6 mm hexagon socket. Bolt can also be removed and
installed with socket -V.A.G 1669- .
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
4. Removing and installing gearbox
105
bearing from crankshaft and driving in .
– Check for proper seating of both dowel sleeves between en‐
gine and gearbox.
– Check for proper seating of intermediate plate.
– Guide selector lever cable as soon as possible into its cable
support bracket.
Check Bowden cable as soon as gearbox is raised. Be sure to
insert it in cable support bracket “early”.
Bowden cable must not be greased.
It must be possible to guide the engine and gearbox together by
hand until the engine flange and gearbox flange make contact all
around.
If not, “something has gone wrong”!
– Readjust gearbox support until engine and gearbox are
“aligned with each other”.
– Turn crankshaft slightly if necessary.
– After fitting starter motor, check that both breather caps are in
place -arrows-!
– Securing clip for selector lever Bowden cable -arrow- must be
renewed.
A securing clip which has been removed is not allowed to be in‐
stalled again. The clip will have lost its internal tension and so it
might fall off.
– Therefore, when installing, always use a “new” securing clip.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
106
If the sheet metal has been bent downwards when the gearbox
was removed, it may cause noises. The cable will vibrate against
the sheet metal.
– Observe sheet metal. Press it back up in the tunnel during
installation.
– Always adjust selector lever cable
⇒ page 43
.
–
Carrying out basic adjustment
⇒ page 7
.
Torque settings for gearbox installation
⇒ page 107
.
4.7
Torque settings “Gearbox to engine”
and notes on assembly mounting
The “next chapters” list the torque settings for gearbox installa‐
tion.
There is also information about the “left” assembly mounting.
Threaded connections that are not directly assigned to the gear‐
box can be found in the associated assembly groups.
For example: subframe and pendulum support.
The pendulum support on the subframe is part of the running
gear.
Consequently, further descriptions can also be found in ⇒ Run‐
ning gear, axles, steering; Rep. Gr. 40 .
Left assembly mounting
– Renew all bolts on left assembly mounting.
– First screw in all bolts by hand.
– First bolt bracket to gearbox -1- with 40 Nm + 90° further turn.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
4. Removing and installing gearbox
107
+ 90°.
Assembly overview - subframe, anti-roll bar, suspension links .
Gearbox to engine:
♦ 1.4 l/90 kW TFSI engine
⇒ page 108
♦ 1.4 l/118 kW TSI engine
⇒ page 108
♦ 1.6 l/75 kW MPI engine
⇒ page 108
♦ 1.9 l/77 kW TDI PD engine
⇒ page 109
♦ 1.6 l/77 kW TDI CR engine
⇒ page 110
4.7.1
Engines: 1.4 l/90 kW TFSI, 1.4 l/118 kW TSI, 1.6 l/75 kW
M12 - 80 Nm
❑ If insert 18 mm -T10179-
is used: 65 Nm.
M10 - 40 Nm
- Arrows point towards dowel
sleeves
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
108
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