Get OperationandHousing -> 2 Transmission, Removing and Installing... Diesel Engine and FWD Guide for Volkswagen Jetta 4 Door Fourth Generation (1999-2005)

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

6-Speed Manual Transmission 02Q - Edition 05.2013

2

Transmission, Removing and Instal‐

ling, Jetta from MY 2005 , Golf Wag‐

on from MY 2007 and Golf Wagon

from MY 2010, Vehicles with Diesel

Engine and FWD

⇒ “2.1 Transmission, Removing and Installing”, page 106

⇒ “6 Transmission, Transporting”, page 189

⇒ “2.2 Tightening Specifications”, page 124

2.1

Transmission, Removing and Installing

Special tools and workshop equipment required

♦ Support Elements for transmission (determine when mounting

the Mounting Plate on the Transmission Support )

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

♦ Transmission Support Jig - 3336- to transport the transmis‐

sion.

♦ Torque Wrench 1331 5-50Nm - VAG1331-

♦ Torque Wrench 1332 40-200Nm - VAG1332-

♦ Engine and Gearbox Jack - VAS6931-

♦ Engine Support Bridge - Gearbox Bracket - T10346-

♦ Engine Support Device - 3300A-

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

♦ Hose Clamps - Up To 25 mm - 3094-

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

♦ Engine Support Bridge - 10-222A-

♦ Engine Support Bridge - Engine Support Feet - 10-222A/8-

♦ Engine Support Bridge - Engine Support 3 - 10-222A/3-

♦ Engine Support Bridge - Engine Support 18 - 10-222A/18-

♦ Transmission Support - 3282-

♦ Allocate the grease for gearshift mechanism. Refer to the

Parts Catalog.

♦ M6 x 20 collar bolt

♦ M6 x 80 collar bolt

♦ M10 x 20 hex bolt

Removing

The Engine Support Bridge - 10-222A- and the Engine Support

Bridge - Engine Support Feet - 10-222A/8- will be mounted on the

longitudinal members later in the procedure.

106

Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

•

To protect the edges of the fender, cover both Engine Support

Bridge - Engine Support Feet - 10-222A/8- with cloth tape

-arrow-. Refer to the Parts Catalog (Chemical Materials).

– 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 .

Later in the procedure, the Engine Support Bridge - 10-222A- is

connected to the engine lifting eyes.

– Remove the engine cover if it is blocking the lifting eyes.

– Remove the air filter housing if it is located near the battery.

Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Air

Filter Housing, Removing and Installing .

– Remove the battery, the battery cover and the battery tray.

Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Bat‐

tery, Removing and Installing .

– Remove the shift cable lock washer -3- from the transmission

shift lever -1- and remove the cable from the pin -arrow-.

Metal Relay Lever

– Remove the selector cable lock washer -4- from the relay lever

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

Plastic Relay Lever

– 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-, tie

up to the side.

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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 strap -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.

108

Rep. Gr.34 - Operation and Housing

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Install the Engine Support Bridge - Gearbox Bracket - T10346-

in the most rear hole out of the three holes in the battery tray.

– Use a collar bolt M6 x 80 or one of the battery tray bolts for

this.

– 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.

– Position the Engine Support Bridge - 10-222A- in front of the

hood support.

– Use:

– Position the Engine Support Bridge - Engine Support Feet -

10-222A/8- :

– Then connect the Engine Support Bridge - Gearbox Bracket -

T10346- to the Engine Support Bridge .

– Hook the Spindles into the left lifting eye on the engine.

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– Pretension the engine/transmission assembly and Engine

Support Bridge - 10-222A- via the spindles.

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 .

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

Gr. 50 ; Noise Insulation .

– Remove the lower part of the left front wheel housing liner.

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

– Transmission on vehicles with Start/Stop System: disconnect

the connector -arrow- from the Transmission Neutral Position

Sensor - G701- .

– Remove the Left Front Level Control System Sensor - G78-

from the control arm, if equipped. Refer to ⇒ Rep. Gr. 40 .

– 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 .

110

Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

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

⇒ Rep. Gr. 19

– 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.

– Remove the pendulum support.

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6-Speed Manual Transmission 02Q - Edition 05.2013

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

sor - G266- .

– Remove the coupling rod from the stabilizer bar and move it

to the side. Refer to ⇒ Suspension, Wheels, Steering; Rep.

Gr. 40 ; Front Suspension and Control Arm .

– 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-.

– Lower the transmission by adjusting the spindles, which are

attached to the engine, to dimension -a- approximately 40 mm.

Note

When moving the engine/transmission assembly, pay attention to

the connection lines, hoses and radiator.

Volkswagen Technical Site:

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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

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

Metal Relay Lever

– Remove the lock washer -arrow- from the relay lever -1- and

then remove the relay lever.

Plastic Relay Lever

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

⇒ “1.8 Plastic Relay Lever”, page 89 .

Continuation for All

– 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 bolt -1-.

Note

Loosen the engine/transmission connecting bolt -3- and leave it

in so that it is hand-tight.

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6-Speed Manual Transmission 02Q - Edition 05.2013

– Tighten the Engine Support Bridge - Gearbox Bracket -

T10346- with the bolt -1- in the left threaded hole in the

subframe.

-1- = M6 x 20 collar bolt

– Secure the Engine Support Device - 3300A- on the Engine

Support Bridge - Gearbox Bracket - T10346- .

– Place a cloth between Engine Support Device - 3300A- and

oil pan.

– Push the engine forward using the spindle on the Engine Sup‐

port Device - 3300A- . Note the following when doing this:

•

The A/C compressor -2- must not touch the refrigerant line

-1- -arrow-.

•

The generator must not touch the refrigerant line.

The pressure pipe must not touch the radiator.

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 - VAG1383A- under the

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

direction of travel.

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

mission.

– 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-.

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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 engine/transmission connecting bolt -arrow- is removed.

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

lower engine/transmission connecting bolts.

– 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-.

– Guide the transmission and the differential over the subframe

-A- and swing it out.

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6-Speed Manual Transmission 02Q - Edition 05.2013

– 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

⇒ “2.1 Transmission, Removing and Installing”, page 106 .

♦ 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).

– 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 .

116

Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– Tighten the Engine Support Bridge - Gearbox Bracket -

T10346- with the bolt -1- in the left threaded hole in the

subframe.

-1- = M6 x 20 collar bolt

– Secure the Engine Support Device - 3300A- on the Engine

Support Bridge - Gearbox Bracket - T10346- .

– Place a cloth between Engine Support Device - 3300A- and

oil pan.

– Push the engine forward using the spindle on the Engine Sup‐

port Device - 3300A- . Note the following when doing this:

•

The A/C compressor -2- must not touch the refrigerant line

-1- -arrow-.

•

The generator must not touch the refrigerant line.

The pressure pipe must not touch the radiator.

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.

Diesel Engine and FWD

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– 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.

118

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

⇒ “2.2 Tightening Specifications”, page 124 .

– Install lower engine/transmission connecting bolts and tighten

to tightening specification. Refer to

⇒ “2.2 Tightening Specifications”, page 124 .

– Remove the Engine Support Device - 3300A- and Engine

Support Bridge - Gearbox Bracket - T10346- .

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

tighten it to the tightening specification. Refer to

⇒ “2.2 Tightening Specifications”, page 124 .

– 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

⇒ “2.2 Tightening Specifications”, page 124 .

– 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) .

Metal Relay Lever

– Install the relay lever -1- and the lock washer -arrow-.

Plastic Relay Lever

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

⇒ “1.8 Plastic Relay Lever”, page 89 .

Continuation for All

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

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

Refer to ⇒ “2.2 Tightening Specifications”, page 124 .

Diesel Engine and FWD

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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-.

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

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

Refer to ⇒ “2.2 Tightening Specifications”, page 124 .

Note

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

Rep. Gr. 10 ; Engine, Removing and Installing .

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 ⇒ “2.2 Tightening Specifications”, page 124 .

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-.

♦ Observe the correct bolts and tightening specifications. Refer

to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe;

Overview - Subframe .

– 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 .

120

Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

– 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 .

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

Steering; Rep. Gr. 40 .

– Install the Left Front Level Control System Sensor - G78- in

the control arm, if equipped. Refer to ⇒ Rep. Gr. 40 .

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

G266- .

– Assemble the exhaust system and install 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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6-Speed Manual Transmission 02Q - Edition 05.2013

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

Gr. 21 .

– Attach 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

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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Rep. Gr.34 - Operation and Housing

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) .

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

shift lever -1-.

Refer to the Parts Catalog for the grease allocation.

– Slide the shift cable onto the respective pins -arrow- and se‐

cure it with a new lock washer -3-.

Metal Relay Lever

– Apply a small amount of grease to the pin -arrow- of the relay

lever -2-.

Refer to the Parts Catalog for the grease allocation.

– Slide the selector cable onto the respective pins -arrow- and

secure it with a new lock washer -4-.

Plastic Relay Lever

– Insert the selector cable into the cable retainer.

Continuation for All

– Adjust the gearshift mechanism. Refer to

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

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

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

moving and Installing .

– If removed, install complete air filter housing. Refer to ⇒ Rep.

Gr. 23 ; Diesel Direct Injection System; Air Filter Housing,

Removing and Installing .

– Install the engine cover if necessary.

– 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 lower part of the left front wheel housing liner. Refer

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

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

50 ; Noise Insulation .

– Check the headlamp adjustment if the vehicle has a Left Front

Level Control System Sensor - G78- . Refer to ⇒ Electrical

Equipment; Rep. Gr. 94 ; Headlamps; Headlamp, Adjusting .

Diesel Engine and FWD

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6-Speed Manual Transmission 02Q - Edition 05.2013

2.2

Tightening Specifications

Transmission to Engine (Engine Flange Face)

Item

1

Bolt

Quantity

1

Nm

80

M12 x 55

♦ With a short M8 threa‐

ded pin

2

M12 x 55

♦ With a long threaded

pin M8

1

80

3

4

5

6

M12 x 65

M10 x 50

M10 x 105

1

2

1

80

40

80

M12 x 165

♦ With a short M8 threa‐

ded pin

♦ Also starter to trans‐

mission

7

-

M12 x 165

♦ With a short M8 threa‐

ded pin

1

80

10

♦ Also starter to trans‐

mission

M6 x 8

♦ Small flywheel cover

plate (not present on all

engines)

-A- and -B-: alignment bushings

Transmission Bracket -1- to Transmission.

– Replace the bolts.

Tighten the bolts -arrows-: 60 Nm + 90°.

124

Rep. Gr.34 - Operation and Housing

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

6-Speed Manual Transmission 02Q - Edition 05.2013

Transmission to Body

– Replace the bolts.

Tighten the bolts -arrows-: 60 Nm + 90°.

Note

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

Rep. Gr. 10 ; Engine, Removing and Installing .

Diesel Engine and FWD

^{2. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010, Vehic}1^les2^w5^ith

OperationandHousing -> 2 Transmission, Removing and Installing... Diesel Engine and FWD for Your Volkswagen Jetta 4 Door Fourth Generation (1999-2005)

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