Get OperationandHousing -> 4.1 Transmission, Removing and Installing Guide for Volkswagen Golf 4 Door Fifth Generation (2003-2008)

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

4

Transmission, Removing and Instal‐

ling, Jetta from MY 11, Diesel and

Gasoline

⇒ “4.1 Transmission, Removing and Installing”, page 145

⇒ “6 Transmission, Transporting”, page 189

⇒ “4.2 Tightening Specifications”, page 164

4.1

Transmission, Removing and Installing

Special tools and workshop equipment required

♦ Engine Support Bridge - 10-222A-

♦ Transmission Support - 3282-

♦ Engine and Gearbox Jack - VAS6931-

♦ Tensioning Strap - T10038-

♦ Engine Support - Basic Set - T40091-

♦ Engine Support - Supplement Kit - T40093A-

♦ Slide Hammer Set - Adapter 40 - VW771/40- from the Slide

Hammer Set - VW771-

♦ Hose Clamps - Up To 25mm - 3094-

♦ Transmission Support - Pins 29 - 3282/29-

♦ Transmission Support - Mounting Plate 33 - 3282/33-

♦ Support Elements for transmission (determine when mounting

the Mounting Plate on the Transmission Support )

♦ Grease for Clutch Disc Shaft Splines - G 000 100-

♦ Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.

♦ M10 x 20 hex bolt

Removing

– See if a coded radio is installed. If so, obtain the anti-theft code.

– Disconnect the battery ground cable. Refer to ⇒ Electrical

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

Connecting .

– Remove the engine cover. Refer to ⇒ Rep. Gr. 15 ; Cylinder

Head; Engine Cover, Removing and Installing .

– Remove the complete air filter housing. Refer to ⇒ Rep. Gr.

23 ; Diesel Direct Injection System; Air Filter Housing, Re‐

moving and Installing or ⇒ Rep. Gr. 24 ; Air Filter; Air Filter

Housing, Removing and Installing .

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– 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 -1- from the transmission

shift lever -2- and remove the cable from the pin -arrow-.

– Remove the cable retainer from the selector cable.

•

To avoid damage to the selector cable, the cable retainer must

be disconnected from the selector lever before removal.

– Pull the securing mechanism all the way forward in direction

of -arrow 1- and then unlock to the left in direction of

-arrow 2-.

– Press the relay lever forward (in the direction of -arrow 3-).

– The relay lever is removed together with the cable retainer

later in the procedure.

– Remove the cable bracket from the transmission -arrows-,

move it to the side and tie it up.

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Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Vehicles with A Pipe between the Clutch Master and Slave Cyl‐

inders

– Clamp the clutch master cylinder hose using a Hose Clamps

- Up To 25mm - 3094- .

Vehicles with A Hose/Line Assembly between the Clutch Master

and Slave Cylinders

– Clamp off the hose on the hose/line assembly -A- to the clutch

slave cylinder using the Hose Clamps - Up To 25mm - 3094- .

Continuation for All

– Pull the clamp -arrow- for the hose/line assembly or the pipe

out all the way to the stop.

– Remove the hose/line assembly or pipe from the bleeder/

clutch slave cylinder and seal it off.

Caution

Do not press the clutch pedal anymore.

– Remove the ground cable -1- from the top starter bolt.

– Disconnect the connector -2- from the Back-Up Lamp Switch

- F4- .

– Disconnect the connector and the wire from the starter.

– Remove the upper engine/transmission connecting bolts

-arrows-.

– Remove the upper bolt from the starter.

– Remove the plenum chamber cover. Refer to ⇒ Body Exterior;

Rep. Gr. 50 ; Plenum Chamber Cover; Plenum Chamber

Cover, Removing and Installing .

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the bolts -arrows- for the left and right lock carrier

retaining brackets.

– Remove the lower mounts on the Engine Support Bridge - En‐

gine Support 28 - 10-222A/28- and replace them with the

Engine Support Bridge - Engine Support 28-2 - 10-222A/

28-2- .

– Remove the bolts -arrows- for securing the engine support

bridge on the lock carrier from the Engine Support Bridge -

Engine Support 28-2 - 10-222A/28-2- .

•

Use the bolts in the Engine Support Bridge - Engine Support

28-2 - 10-222A /28-2- for attaching the Engine Support Bridge

- Engine Support 28 - 10-222A /28- . Not the bolts for the re‐

taining bracket.

– Install the Engine Support Bridge - Engine Support 28 -

10-222A/28- and tighten the bolts to 8 Nm -arrows-.

Caution

A second technician is needed to mount the Engine Support

Bridge - 10-222A- on the vehicle to prevent the Engine Support

Bridge - 10-222A- from tipping.

– If there are hose and cable connections located near the en‐

gine lifting eyes for the Engine Support Bridge - 10-222A- ,

these must now be removed.

Vehicles with Diesel Engines

Install the Engine Support Bridge - 10-222A- as shown.

– First slide the Moveable Joints -2- onto the Square Pipe from

the Engine Support Bridge - 10-222A- .

– Mount the Engine Support Bridge - 10-222A- on the suspen‐

sion strut towers and have a second technician hold it to

prevent it from tipping.

– Push the Engine Support - Basic Set - Square Pipe -

T40091/1- -6- from the front left and right through the Engine

Support Bridge - Engine Support 28 - 10-222A/28- -7- and

place on each side of the Engine Support - Supplement Kit -

Movable Joint - T40093/4- -5-.

– Slide the Engine Support - Basic Set - Rail with Holes -

T40091/2- -4- with the Engine Support - Supplement Kit Mount

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6-Speed Manual Transmission 02Q - Edition 05.2013

- T40093/5- -9- in the Engine Support - Supplement Kit -

Moveable Joint - T40093/4- -5-.

– Install the locking pins into the Engine Support - Basic Set -

Rail with Holes - T40091/2- -4- and secure it with the cotter

pins.

1 - Engine Support Bridge - En‐

gine Support 31 - Adapter 2 -

10-222A/31-2-

2 - Engine Support - Basic Set

- Moveable Joint - T40091/3-

3 - Engine Support Bridge - En‐

gine Support 31 - Adapter 1 -

10-222A/31-1-

4 - Engine Support - Basic Set

- Rail with Holes - T40091/2-

5 - Engine Support - Supple‐

ment Kit - Movable Joint -

T40093/4-

6 - Engine Support - Basic Set

- Square Pipe - T40091/1-

7 - Engine Support Bridge - En‐

gine Support 28 - 10-222A/28-

with Engine Support Bridge -

Engine Support 28-2 -

10-222A/28-2-

8 - Engine Support Bridge -

Spindle - 10-222A/11-

9 - Engine Support - Supple‐

ment Kit - Mount 5 - T40093/5-

10 - Engine Support - Bracket

w/Spindle and Hook -

10-222A/10-

Vehicles with Gasoline Engine

Install the Engine Support Bridge - 10-222A- as shown.

– First slide the Moveable Joints -2- onto the Square Pipe from

the Engine Support Bridge - 10-222A- .

– Mount the Engine Support Bridge - 10-222A- on the suspen‐

sion strut towers and have a second technician hold it to

prevent it from tipping.

– Push the Engine Support - Basic Set - Square Pipe -

T40091/1- -5- from the front left and right through the Engine

Support Bridge - Engine Support 28 - 10-222A /28- -6- and

place on each side of the Engine Support - Supplement Kit -

Movable Joint - T40093/4- -4-.

– Push the Engine Support - Basic Set - Rail with Holes -

T40091/2- -7- with the Engine Support - Supplement Kit -

Mount - T40093/5- -8- in the Engine Support - Supplement Kit

- Movable Joint - T40093/4- -4-.

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the locking pins into the Engine Support - Basic Set -

Rail with Holes - T40091/2- -7- and secure it with the cotter

pins.

1 - Engine Support Bridge - En‐

gine Support 31 - Adapter 2 -

10-222A/31-2-

2 - Engine Support - Basic Set

- Moveable Joint - T40091/3-

3 - Engine Support Bridge - En‐

gine Support 31 - Adapter 1 -

10-222A/31-1-

4 - Engine Support - Supple‐

ment Kit - Movable Joint -

T40093/4-

5 - Engine Support - Basic Set

- Square Pipe - T40091/1-

6 - Engine Support Bridge - En‐

gine Support 28 - 10-222A/28-

with Engine Support Bridge -

Engine Support 28-2 -

10-222A/28-2-

7 - Engine Support - Basic Set

- Rail with Holes - T40091/2-

8 - Engine Support - Supple‐

ment Kit - Mount 5 - T40093/5-

9 - Engine Support Bridge -

Spindle - 10-222A/11-

❑ Engaged in the engine

lifting eye -arrow-.

All Vehicles

– Tighten all the threaded connections on the Engine Support

Bridge - 10-222A- hand-tight. While doing so, adjust the height

of the Engine Support Bridge - 10-222A- parallel over the En‐

gine Support Bridge - Engine Support 28 - 10-222A/28- .

– Pretension the engine/transmission assembly with the spin‐

dles, but do not lift.

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Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

The left drive axle must be removed later in the procedure.

– With the vehicle still standing on its wheels, loosen the left front

collar bolt -arrow- a maximum 90°, otherwise the wheel bear‐

ing will get damaged. Refer to ⇒ Suspension, Wheels, Steer‐

ing; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

– Loosen the left front wheel bolts.

– Lift the vehicle, all four take-up points of lifting platform at the

same height.

– Remove the left front wheel.

– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.

Gr. 50 ; Noise Insulation .

– Remove the left front housing liner. Refer to ⇒ Body Exterior;

Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel Housing Lin‐

er, Removing and Installing .

– Transmission on vehicles with Start/Stop System: disconnect

the connector -arrow- from the Transmission Neutral Position

Sensor - G701- .

– Remove the bracket from the starter.

– Remove the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.

27 ; Starter; Starter, Removing and Installing .

– Remove the left charge air hose -arrow 1 and arrow 2- ⇒ Rep.

Gr. 21 .

– Remove the charge air pipe from the engine. Refer to ⇒ Rep.

Gr. 21 .

– Remove the right charge air hose from the charge air cooler.

Refer to ⇒ Rep. Gr. 21 .

– Remove the air shroud -arrow- and the radiator fans. Refer to

⇒ Rep. Gr. 19

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6-Speed Manual Transmission 02Q - Edition 05.2013

Vehicles with Gasoline Engine

– Remove the front exhaust pipe from the turbocharger

(-arrow-). Refer to ⇒ Rep. Gr. 26 .

Vehicles with Diesel Engines

– Remove the exhaust system bracket from the subframe

-arrows-. Refer to ⇒ Rep. Gr. 26 .

– Disconnect the exhaust system at the double clamp -arrows-.

– Tie up the front exhaust pipe or lay it on the tunnel brace.

All Vehicles

– Remove the pendulum support.

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Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Disconnect the connector -1- from the Oil Level Thermal Sen‐

sor - G266- .

– Remove left coupling rod from stabilizer bar and set off to the

side. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 .

– Remove the left drive axle. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

– If equipped remove the drive axle heat shield -arrows-. Refer

to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles,

Overview and Servicing; Drive Axle Heat Shield .

– Remove the right drive axle from the transmission and tie it up.

Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive

Axles, Removing and Installing .

– Remove the hex collar bolts -arrows- on the left subframe

mount -2- from the left bracket -1-.

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Lower the engine/transmission approximately 40 mm to di‐

mension -a- using the spindles on the Engine Support Bridge

- 10-222A- .

Note

When moving the engine/transmission assembly, pay attention to

the connection lines, hoses and radiator.

– Remove the bracket -1- from the transmission -arrows-.

– Remove the relay lever with the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89 .

– Remove the gearshift lever from the gearshift shaft.

– Remove the small flywheel cover plate -A- -arrows-, if equip‐

ped.

– Remove the lower engine/transmission connecting bolts -2-.

Note

Loosen the engine/transmission connecting bolts -1 and 3- and

let them be hand-tight.

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Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Align the Transmission Support - 3282- with the Transmission

Support - Mounting Plate 33 - 3282/33- in order to remove the

“02Q” transmission.

– Insert the Transmission Support - 3282- into the Engine and

Gearbox Jack - VAS6931- .

– Align the arms of the Transmission Support - 3282- so that

they match up with the holes in the Adjustment Plate .

– Install the Support Elements -A- as illustrated on the Adjust‐

ment Plate .

– Install the Transmission Support - Pins 29 - 3282/29- in place

of the Mounting Element -C-.

– Position the Engine-Gearbox Jack - VAG1383 A- under the

vehicle. The arrow symbol -B- on the Adjusting Plate points in

direction of travel.

– Align the Adjusting Plate so that it is parallel to the transmis‐

sion.

– Secure the Slide Hammer Set - Adapter 40 - VW771/40- inside

the threaded hole in the transmission housing as shown.

– Install the Transmission Support - Pins 29 - 3282/29- into the

hole on the transmission for the pendulum support bolt.

– Secure the transmission on the Transmission Support - 3282-

with an M10 x 20 bolt -A-.

The drift -B- must be flush at the bottom with the guide on the

Transmission Support - 3282- -arrow-.

– Remove the engine/transmission connecting bolt -C-.

– Remove the last transmission to engine connecting bolt

-arrow-.

– Separate the transmission from the engine (alignment

sleeves).

– Move the transmission in the area of the differential with the

spindles of the Transmission Support - 3282- into an angled

position.

•

The differential, near the transmission, must face upward.

The right flange shaft -1- must be guided over the bolting eyelet

of the engine -2-.

– Carefully push the engine forward slightly with a second tech‐

nician.

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Guide the transmission and the differential over the subframe

-A- and swing it out.

– Pay attention to the longitudinal member -arrows-. Then care‐

fully lower the transmission.

Note

Pay attention to all of the lines when lowering the transmission.

Installing

Note

♦ Refer to “Transmission, Removing” to get a list of the special

tools needed. Refer to

⇒ “4.1 Transmission, Removing and Installing”, page 145 .

♦ Replace the self-locking nuts and bolts.

♦ Replace bolts that were tightened with an additional turn.

♦ Install any cable ties that were loosened or cut off during re‐

moval at their same location.

♦ Clean the input shaft splines and (on used clutch plates) the

hub splines. Remove any corrosion and then apply a very thin

coat of Grease for Clutch Disc Shaft Splines - G 000 100- on

the splines. Then move the clutch plate back and forth on the

input shaft until the hub moves freely on the shaft. Excess

grease must be removed.

– If the transmission is replaced, transfer the transmission shift

lever and the relay lever.

– Clean any locking compound residue from all threaded holes

using a tap.

– Check whether there are centering sleeves for the engine/

transmission in the cylinder block; install if necessary.

If the alignment sleeves are missing, it will be difficult to shift, there

will be clutch problems and the transmission may make noises

(loose rattling).

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Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Make sure the intermediate plate is engaged on the sealing

flange and pushed onto the alignment sleeves -arrows-.

– Check the release bearing for wear. Replace the clutch slave

cylinder with release bearing if necessary. Refer to

⇒ “2.2 Clutch Slave Cylinder with Release Bearing, Removing

and Installing”, page 52 .

Align the Transmission Support - 3282- with the Transmission

Support - Mounting Plate 33 - 3282/33- in order to install the “02Q”

transmission.

– Align the arms of the Transmission Support - 3282- so that

they match up with the holes in the Adjustment Plate .

– Install the Support Elements -A- as illustrated on the Adjust‐

ment Plate .

– Install the Transmission Support - Pins 29 - 3282/29- in place

of the Mounting Element -C-.

– Place the transmission on the Engine and Gearbox Jack -

VAS6931- .

– Align the Adjustment Plate so that it is parallel to the trans‐

mission.

– Install the Transmission Support - Pins 29 - 3282/29- into the

hole on the transmission for the pendulum support bolt.

– Secure the Slide Hammer Set - Adapter 40 - VW771/40- inside

the threaded hole in the transmission housing as shown.

– Secure the transmission on the Transmission Support - 3282-

with an M10 x 20 bolt -A-.

The drift -B- must be flush at the bottom with the guide on the

Transmission Support - 3282- -arrow-.

– Position the Engine and Gearbox Jack - VAS6931- under the

vehicle. The arrow on the adjusting plate points in direction of

travel.

Note

Pay attention to all of the lines when installing the transmission.

– Lift the transmission carefully.

– Carefully push the engine forward slightly with a second tech‐

nician.

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Now turn the transmission upward in the area of the differential

and downward in the area of the 6th gear via the spindles of

the Transmission Support - 3282- .

– Guide the transmission and differential -A- over the subframe.

•

The right flange shaft must be guided past the flywheel

-arrow 2-; pay attention to the intermediate plate -arrow 1-.

– The right flange shaft -1- must be guided over the bolting eye‐

let of the engine -2-.

– At the same time, change the position of the transmission us‐

ing the spindles of the Transmission Support - 3282- so that it

does not come into contact with the longitudinal member

-arrows-.

– Turn the transmission to its installed position using the spin‐

dles of the Transmission Support - 3282- .

– Align the transmission to the engine (alignment sleeves) and

insert it.

Caution

♦ Brake fluid can escape from the bleeder on the transmis‐

sion.

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Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Insert engine/transmission bolt -C- and tighten to tightening

specification. Refer to

⇒ “4.2 Tightening Specifications”, page 164 .

– Install lower engine/transmission connecting bolts and tighten

to tightening specification. Refer to

⇒ “4.2 Tightening Specifications”, page 164 .

– Install the engine/transmission connecting bolt -arrow- and

tighten it to the tightening specification. Refer to

⇒ “4.2 Tightening Specifications”, page 164 .

– After transmission is bolted to engine at bottom, remove the

Transmission Support - 3282- from transmission.

– Install the upper engine/transmission connecting bolts and

tighten them to the tightening specification. Refer to

⇒ “4.2 Tightening Specifications”, page 164 .

– Attach the transmission gearshift lever to the gearshift shaft.

Refer to

⇒ Fig. ““Installing the Transmission Shift Lever”“ , page 88 and

tighten the nut to tightening specification -item 17-

⇒ Item 17 (page 87) .

– Install the relay lever with the cable retainer. Refer to

⇒ “1.8 Plastic Relay Lever”, page 89 .

– Attach the bracket -1- with the new hex bolts to the transmis‐

sion -arrows- and tighten them to the tightening specification.

Refer to ⇒ “4.2 Tightening Specifications”, page 164 .

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Align the engine/transmission in its installed position. Lift it un‐

til the bracket -1- is in complete contact with the left subframe

mount -2-.

Caution

There is a risk of damaging the threads in transmission bracket

by inserting bolts at an angle.

♦ Before installing bolts -arrows-, transmission bracket and

transmission mount support arm must be absolutely par‐

allel to each other. If necessary, lift the back of the trans‐

mission using the Engine and Gearbox Jack - VAS6931- .

Note

Install the engine/transmission mount free of tension. Refer to ⇒

Rep. Gr. 10 .

– Install the new hex bolts -arrows- of the left subframe mount

-2- in the bracket -1- and tighten to the tightening position.

Refer to ⇒ “4.2 Tightening Specifications”, page 164 .

WARNING

Only remove the Engine Support Bridge - 10-222A- when all

subframe mount bolts are tightened to the tightening specifi‐

cation.

– Install the flywheel cover plate -A- (if equipped) -arrows-. Refer

to ⇒ “4.2 Tightening Specifications”, page 164 .

Note

♦ There are threaded inserts (for example “Heli Coil”) in the pen‐

dulum support fastening holes.

♦ Characteristic: there is a collar on the first thread -arrow-.

♦ Pay attention to the corresponding bolts and tightening spec‐

ifications. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr.

40 ; Subframe; Overview - Subframe .

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Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the pendulum support. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Subframe; Overview - Subframe .

– Install the drive axles. Refer to ⇒ Suspension, Wheels, Steer‐

ing; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

– If equipped install the drive axle heat shield -arrows-. Refer to

⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles,

Overview and Servicing; Drive Axle Heat Shield .

– Attach the left coupling rod. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 .

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

G266- .

– Assemble the exhaust system and attach the exhaust system

bracket to the subframe. Refer to ⇒ Rep. Gr. 26 .

– Install the air shroud -arrow- and the radiator fans. Refer to ⇒

Rep. Gr. 19

– Attach the charge air pipe to the engine. Refer to ⇒ Rep. Gr.

21 .

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– Install the left charge air hose -arrow 1- and -arrow 2- ⇒ Rep.

Gr. 21 .

– Install the right charge air hose to the charge air cooler. Refer

to ⇒ Rep. Gr. 21 .

– Position the starter and install the lower bolt. Refer to ⇒ Elec‐

trical Equipment; Rep. Gr. 27 ; Starter; Starter, Removing and

Installing .

– Attach the bracket for the lines to the lower starter bolt.

– Install the starter bolt and then connect the connector and

wires to the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.

27 ; Starter; Starter, Removing and Installing .

– Attach the ground cable -1- to the top starter bolt.

– Connect the connector -2- to the Back-Up Lamp Switch - F4- .

– Transmission on vehicles with Start/Stop System: connect the

connector -arrow- to the Transmission Neutral Position Sensor

- G701- .

– Push the hose/line assembly or pipe -A- into the bleeder/clutch

slave cylinder to the stop and push the clamp -arrow- down‐

ward.

– Pull on the line to make sure it is secure.

– Remove the Hose Clamps - Up To 25mm - 3094- from the

hose/line assembly or from the supply hose.

– After removing the Hose Clamps - Up To 25mm - 3094- , bring

the return hose back to its original shape.

– Bleed the clutch mechanism. Refer to

⇒ “1.10 Clutch Mechanism, Bleeding”, page 48 .

– Make sure the vacuum hose for the brake system is installed

correctly. Refer to ⇒ Brake System; Rep. Gr. 47 ; Hydraulic

System .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Attach the cable mounting bracket to the transmission and

tighten the bolts and nuts -arrows- to the tightening specifica‐

tion -item 6- ⇒ Item 6 (page 86) and -item 10-

⇒ Item 10 (page 86) .

– Insert the selector cable into the cable retainer.

– Apply a small amount of grease to the pin -arrow- on the gear‐

shift lever -2-.

Refer to the Parts Catalog for the grease allocation.

– Replace the lock washer -1- after every disassembly.

– Adjust the gearshift mechanism. Refer to

⇒ “1.11 Selector Mechanism, Adjusting”, page 97 .

– Install the plenum chamber cover. Refer to ⇒ Body Exterior;

Rep. Gr. 50 ; Plenum Chamber Cover; Plenum Chamber

Cover, Removing and Installing .

– Install the bolts -arrows- for the left and right lock carrier re‐

taining brackets to the tightening specification. Refer to ⇒

Body Exterior; Rep. Gr. 50 ; Lock Carrier; Lock Carrier - At‐

tachments .

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

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

stalling .

– Install the air filter. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct

Injection System; Air Filter Housing, Removing and Installing

or ⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and

Installing .

– Install the engine cover. Refer to ⇒ Rep. Gr. 15 ; Cylinder

Head; Engine Cover, Removing and Installing .

– Connect the battery and observe procedure after connecting

battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;

Battery, Disconnecting and Connecting .

– Check the transmission fluid level. Refer to

⇒ “8 Transmission Fluid, Checking”, page 192 .

– Install the left front housing liner. Refer to ⇒ Body Exterior;

Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel Housing Lin‐

er, Removing and Installing .

– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.

50 ; Noise Insulation .

– Install the wheel. Refer to ⇒ Suspension, Wheels, Steering;

Rep. Gr. 44 ; Wheel Installation Tightening Specifications .

4. Transmission, Removing and Installing, Jetta from MY 11, Diesel and Gasoline

163

OperationandHousing -> 4.1 Transmission, Removing and Installing for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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