Руководство по эксплуатации volkswagen golf 2007

Панель управления автомобилем
1 — внутренняя ручке водительской двери 2 — клавиша центрального замка 3 — переключатель наружного освещения 4 — боковые дефлекторы 5 — регуля…

Щиток приборов
1 — кнопки настройки часов 2 — тахометр 3 — указатель температуры охлаждающей жидкости 4 — дисплей 5- указатель запаса топлива 6 — спидомет…

Дисплей в приборном щитке
1 — сигнальные лампочки 2 — часы. У некоторых моделей справа от часов находится указатель температуры наружного воздуха 3 — счетчики пробега или инд…

Бортовой компьютер (MFA)
Бортовой компьютер выдает различные данные по поездке, которые выводятся на дисплей приборного щитка. Подрулевой рычаг очистителя и омывателей стекла В с к…

Ключи для автомобиля
Ключи А с встроенным пультом дистанционного управления и пластиковый брелок В с номером ключей представлены на иллюстрации. На основании номера ключе…

Центральный замок
Центральный замок обеспечивает централизованное отпирание и запирание всех дверей, включая заднюю дверь. Управление центральным замком осуществляется…

Дистанционное управление замками
Запирание и отпирание автомобиля При помощи пульта дистанционного управления замками можно запирать и отпирать автомобиль на расстоянии. Кнопкой на пу…

Нет изображения

Управление отопителем
Выключатели отопителя Переключателями 1, 5 и клавишей 6 выберите температуру, направление обдува салона и объем подаваемого в салон воздуха. Для…

Управление кондиционером
Выключатели кондиционера Кондиционер работает только при запущенном двигателе и включенном вентиляторе. Переключателями 1, 6 и клавишей 7 выбери…

Управление климат-контролем
1 — температура на левой стороне салона. 2 — режим рециркуляции воздуха в салоне . 3 — обдув середины салона . 4 — обдув пола . 5 — об…

Замок зажигания
0 — зажигание выключено, рулевое управление заблокировано Для блокировки рулевого управления при вынутом из замка ключе зажигания несколько поверните…

Механическая коробка передач
Схема переключения 5-ступенчатой механической коробки передач: Схема переключения 6-ступенчатой механической коробки передач: …

Автоматическая коробка передач
Автоматическая коробка передач имеет две программы — D и S. При установке рычага управления в положение D коробка передач работает в экономичном режи…

Включение круиз-контроля
Круиз-контроль поддерживает постоянной заданную скорость движения в диапазоне примерно от 30 до 180 км/час. Управление круиз-контролем выполняется с помощь…

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Manuals and User Guides for Volkswagen Golf Variant 2007. We have 12 Volkswagen Golf Variant 2007 manuals available for free PDF download: Workshop Manual, Repair Manual, Maintenance Manual, Service Manual

Volkswagen Golf Variant 2007 Workshop Manual

Volkswagen Golf Variant 2007 Workshop Manual (515 pages)

Electrical system

Brand: Volkswagen
|
Category: Automobile
|
Size: 13.1 MB

Table of Contents
  • Table of Contents

    3

  • Starter, Current Supply, CCS

    9

  • Battery a

    9

  • Types of Battery

    9

  • Warning Notices and Safety Regulations

    9

  • Battery Terminal Connection

    9

  • Checking Battery a

    10

  • Charging Battery a

    11

  • Disconnecting and Connecting Battery a

    12

  • Disconnecting and Connecting Battery a ( Battery a in Engine Compartment)

    12

  • Removing and Installing Battery a

    15

  • Removing and Installing Battery a ( Battery a in Engine Compartment)

    15

  • Starter B

    21

  • Checking Starter B

    21

  • Removing and Installing Starter B (Automatic Gearbox)

    22

  • Removing and Installing Starter B (DSG)

    43

  • Removing and Installing Starter B (Manual Gearbox)

    68

  • Alternator C

    96

  • Securing Battery Positive Wire on Alternator C

    96

  • Checking Poly V-Belt

    96

  • Checking Alternator C

    97

  • Alternator C 1.4L Petrol Engine

    98

  • Alternator C 1.4L FSI Engine

    103

  • Alternator C 1.4L, TSI Engine

    108

  • Alternator C 1.6L Petrol Engine

    114

  • Alternator C 1.6L FSI Engine

    118

  • Alternator C 2.0L FSI Engine

    122

  • Alternator C 2.0L TFSI Engine

    129

  • Alternator C 2.5L Petrol Engine

    136

  • Alternator C 1.9L Diesel Engine

    139

  • Alternator C 1.9L Diesel Engine with Diesel Particle Filter

    146

  • Alternator C 2.0L SDI Engine

    152

  • Alternator C 2.0L Diesel Engine

    156

  • Alternator C 2.0L CR Diesel Engine

    161

  • Alternator C 2.0L TSI Engine

    166

  • Removing and Installing Poly-V Belt Pulley on Alternator C

    171

  • Voltage Regulator C1 for Alternator C

    176

  • Cruise Control System (CCS)

    180

  • Gauges, Instruments

    181

  • Dash Panel Insert

    181

  • Renewing Dash Panel Insert

    181

  • Removing and Installing Dash Panel Insert (up to MY2009)

    182

  • Removing and Installing Dash Panel Insert (from MY2010)

    183

  • Back of Dash Panel Insert (up to MY2009)

    184

  • Back of Dash Panel Insert (from MY2010)

    184

  • Pin Assignment of Connectors at Dash Panel Insert

    184

  • Warning Lamp Symbols on Dash Panel Insert (up to MY2009)

    184

  • Warning Lamp Symbols on Dash Panel Insert (from MY2010)

    186

  • Service Interval Display

    188

  • Resetting Service Interval Display

    188

  • Windscreen Wash/Wipe System

    189

  • Windscreen Wiper System

    189

  • Deactivating Wiper Motor Control Unit J400 APP Function

    189

  • Assembly Overview — Windscreen Wiper System

    191

  • Removing and Installing Windscreen Wiper System

    191

  • Removing and Installing Wiper Arms

    196

  • Adjusting Wiper Blade Park Position

    196

  • Removing and Installing Joint-Free Wiper Blades

    198

  • Removing and Installing Rain and Light Sensor G397

    198

  • Coding Rain and Light Sensor G397

    200

  • Windscreen Washer System

    202

  • Assembly Overview — Windscreen Washer System

    202

  • Removing and Installing Washer Fluid Reservoir

    203

  • Removing and Installing Windscreen and Rear Window Washer Pump V59

    205

  • Removing and Installing Windscreen Washer Fluid Level Sender G33

    206

  • Removing and Installing Windscreen Washer System Spray Jets

    207

  • Adjusting Windscreen Washer System Spray Jets

    207

  • Rear Window Wiper System

    208

  • Assembly Overview — Rear Window Wiper System

    208

  • Removing Rear Window Wiper

    208

  • Adjusting Rear Window Wiper Park Position

    210

  • Removing and Installing Joint-Free Wiper Blades

    211

  • Rear Window Washer System

    213

  • Assembly Overview — Rear Window Washer System

    213

  • Removing and Installing Washer Jet

    214

  • Adjusting Spray Jet

    214

  • Headlight Washer System

    215

  • Assembly Overview — Headlight Washer System

    215

  • Removing and Installing Headlight Washer System Pump V11

    216

  • Removing and Installing Spray Jet Pop-Up Cylinders

    217

  • Removing and Installing Spray Jet Assembly

    217

  • Adjusting Headlight Washer System Spray Jets

    218

  • Bleeding Headlight Washer System

    218

  • Washer Fluid Line Hose Couplings

    220

  • Hose Repair

    221

  • Lights, Bulbs, Switches — Exterior

    222

  • Headlights with Halogen Bulbs (up to MY2009)

    222

  • Assembly Overview

    222

  • Removing and Installing Headlight

    223

  • Adjusting Headlight Installation Position

    225

  • Renewing Bulbs

    226

  • Removing and Installing Headlight Range Control Motor

    232

  • Repairing Headlight Retaining Tabs

    239

  • Converting Headlights for Use When Driving on the Left or Right

    241

  • Adjusting Headlights

    243

  • Headlights with Halogen Bulbs (from MY2009)

    244

  • General Description

    244

  • Assembly Overview

    244

  • Removing and Installing Headlight

    246

  • Adjusting Headlight Installation Position

    248

  • Renewing Bulbs

    249

  • Removing and Installing Headlight Range Control Motor

    255

  • Repairing Headlight Securing Tabs

    259

  • Converting Headlights for Use When Driving on the Left or Right

    262

  • Adjusting Headlights

    265

  • Headlights with Gas Discharge Bulbs (up to MY2009)

    266

  • Operation and Safety Notes for Gas Discharge Bulbs

    266

  • Assembly Overview

    269

  • Removing and Installing Headlight

    270

  • Adjusting Headlight Installation Position

    270

  • Renewing Bulbs

    270

  • Removing and Installing Headlight Range Control Motor

    276

  • Removing and Installing Gas Discharge Light Control Unit

    279

  • Control Unit for Headlight Range Control J431

    280

  • Vehicle Level Sender

    283

  • Repairing Headlight Securing Tabs

    284

  • Converting Headlights for Use When Driving on the Left or Right

    285

  • Adjusting Headlights

    285

  • Headlights with Gas Discharge Bulbs and Cornering Lights (from MY2010)

    286

  • General Description

    286

  • Assembly Overview

    287

  • Removing and Installing Headlight

    288

  • Adjusting Headlight Installation Position

    290

  • Renewing Bulbs

    290

  • Headlight Starter for Gas Discharge Bulb

    295

  • Power Output Module for Headlight

    296

  • Headlight Range Control Unit J431

    298

  • Headlight Range Control Motor

    300

  • Swivel Module Position Sensor

    300

  • Headlight Screen Adjustment Solenoid

    301

  • Vehicle Level Sender

    302

  • LED Module for Daytime Running Light and Side Light

    302

  • Converting Headlights for Use When Driving on the Left or Right

    302

  • Repairing Headlight Securing Tabs

    304

  • Adjusting Headlights

    304

  • Fog Lights

    305

  • Assembly Overview — Fog Lights (up to MY2009)

    305

  • Assembly Overview — Fog Lights (from MY2010)

    306

  • Removing and Installing Fog Lights (up to MY2009)

    306

  • Removing and Installing Fog Lights (from MY2010)

    307

  • Removing and Installing Fog Light/Cornering Light Bulb

    308

  • Adjusting Fog Lights

    309

  • Bulb for Turn Signal Repeater Light and Entry Light in Exterior Mirror

    310

  • Removing and Installing Turn Signal Bulb

    310

  • Removing and Installing Entry Light in Exterior Mirror

    310

  • Removing and Installing Front Side Marker Light in Front Bumper

    313

  • Rear Side Marker Bulb (Usa/Canada Only)

    314

  • Tail Lights

    315

  • Assembly Overview — Tail Light in Side Panel (Bulbs) — Saloon

    315

  • Removing and Installing Tail Light in Side Panel (Bulbs) — Saloon

    315

  • Removing and Installing Tail Light Bulb Carrier in Side Panel — Saloon

    316

  • Tail Light in Side Panel (LED) — Saloon

    317

  • Removing and Installing Tail Light in Side Panel (LED) — Saloon

    317

  • Assembly Overview — Tail Light in Rear Lid — Saloon

    318

  • Removing and Installing Tail Light in Rear Lid — Saloon

    319

  • Removing and Installing Tail Light Bulb Holder in Rear Lid — Saloon

    319

  • Assembly Overview — Tail Light — Variant

    321

  • Removing and Installing Tail Light — Variant

    321

  • Removing and Installing Tail Light Bulb Holder — Variant

    322

  • Removing and Installing Number Plate Lights

    323

  • Additional Brake Lights

    324

  • Removing and Installing Additional Brake Light Bulb M25 — Saloon

    324

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Volkswagen Golf Variant 2007 Workshop Manual

Volkswagen Golf Variant 2007 Workshop Manual (372 pages)

Brand: Volkswagen
|
Category: Automobile
|
Size: 12.72 MB

Table of Contents

  • Table of Contents

    3

  • Golf Variant 2007 ➤ , Jetta

    10

  • Body — Front

    11

    • Lock Carrier

      11

    • Tools

      11

    • Assembly Overview — Lock Carrier, Service Position

      12

    • Service Position

      12

    • Removing and Installing Lock Carrier with Add-On Parts

      14

    • Wing

      16

    • Tools

      16

    • Assembly Overview — Front Wing

      17

    • Removing and Installing Wing

      17

    • Removing and Installing Wing Bracket

      18

    • Noise Insulation

      20

    • Tools

      20

    • Assembly Overview — Noise Insulation

      21

    • Underbody Cladding

      22

    • Tools

      22

    • Assembly Overview — Underbody Cladding

      23

    • Assembly Overview — Rear Underbody Cladding

      24

    • Plenum Chamber Bulkhead

      25

    • Tools

      25

    • Assembly Overview — Plenum Chamber Bulkhead

      25

  • Bonnet, Rear Lid

    26

    • Bonnet

      26

    • Tools

      26

    • Assembly Overview — Bonnet

      27

    • Removing and Installing Bonnet

      27

    • Removing Gas Strut

      29

    • Releasing Gas from Gas Strut

      29

    • Removing and Installing Lid Hinge

      29

    • Removing and Installing Insulation

      30

    • Assembly Overview — Bonnet Latch and Release Components

      33

    • Removing and Installing Bonnet Lock

      33

    • Disconnecting Bowden Cable

      34

    • Adjusting Bonnet

      35

    • Removing and Installing Release Lever

      37

    • Rear Lid (Saloon)

      39

    • Tools

      39

    • Assembly Overview — Rear Lid

      39

    • Removing and Installing Rear Lid

      40

    • Removing Gas Strut

      40

    • Releasing Gas from Gas Strut

      41

    • Removing and Installing Lid Hinge

      41

    • Removing and Installing Striker Pin

      42

    • Adjusting Rear Lid

      43

    • Assembly Overview — Lid Lock and Lock Cylinder Carrier

      45

    • Removing and Installing Lock Cylinder

      45

    • Removing and Installing Handle Trim

      46

    • Removing and Installing Lid Lock

      46

    • Rear Lid Seal

      47

    • Removing and Installing Rear Lid Seal

      48

    • Rear Lid (Variant)

      49

    • Tools

      49

    • Assembly Overview — Rear Lid

      49

    • Removing and Installing Rear Lid

      50

    • Removing and Installing Gas Strut

      51

    • Releasing Gas from Gas Strut

      52

    • Removing and Installing Rear Lid Hinge

      52

    • Adjusting Rear Lid

      54

    • Removing and Installing Release Button

      57

    • Removing and Installing Lid Lock

      58

    • Rear Lid Seal

      60

    • Removing and Installing Rear Lid Seal

      61

    • Registration Plate Carrier

      63

    • Fuel Tank Flap Unit (Saloon)

      64

    • Assembly Overview — Tank Flap Unit

      64

    • Removing and Installing Tank Flap Unit

      64

    • Removing and Installing Tank Filler Flap Locking Motor V155

      66

    • Fuel Tank Flap Unit (Variant)

      68

    • Assembly Overview — Tank Flap Unit

      68

    • Removing and Installing Tank Flap Unit

      68

    • Removing and Installing Tank Filler Flap Locking Motor V155

      70

  • Front Doors, Door Components, Central Locking

    73

    • Front Door

      73

    • Tools

      73

    • Materials

      74

    • Assembly Overview — Door Assembly

      74

    • Assembly Overview — Door Hinges

      76

    • Removing and Installing Door

      78

    • Adjusting Door

      80

    • Removing and Installing Outer Panel on Door

      83

    • Installing New Outer Panel on Door

      86

    • Removing and Installing Retaining Rail on Door Outer Panel

      90

    • Installation Notes for Bonding a New Outer Panel on Door

      92

    • Minimum Curing Period

      92

    • Cleaning off Excess Adhesive Sealing Material

      93

    • Assembly Overview — Door Inner Part

      94

    • Assembly Overview — Door Handle and Door Lock

      95

    • Removing and Installing Housing

      96

    • Removing and Installing Door Handle

      96

    • Removing and Installing Bearing Bracket

      99

    • Removing and Installing Door Lock

      100

    • Assembly Overview — Side Impact Protection

      102

    • Door Inner Seal

      102

    • Removing and Installing Door Inner Seal

      103

    • Removing and Installing Door Outer Seal

      104

    • Central Locking

      108

    • Fitting Location Overview — Central Locking Components

      108

    • Adapting Keys with Remote Control

      110

    • Assembly Overview — Battery for Folding Key with Remote Control

      110

    • Removing and Installing Battery for Folding Key with Remote Control

      111

  • Rear Doors, Door Components

    112

    • Rear Door (Saloon)

      112

    • Tools

      112

    • Materials

      113

      • Assembly Overview — Door Assembly

        113

      • Assembly Overview — Door Hinges

        115

      • Removing and Installing Door

        117

      • Adjusting Door

        119

      • Removing and Installing Outer Panel on Door

        122

      • Installing New Outer Panel on Door

        125

      • Removing and Installing Retaining Rail on Door Outer Panel

        129

      • Installation Notes for Bonding a New Outer Panel on Door

        131

      • Minimum Curing Period

        131

      • Cleaning off Excess Adhesive Sealing Material

        132

      • Assembly Overview — Door Inner Part

        133

      • Assembly Overview — Door Handle and Door Lock

        134

      • Removing and Installing Housing

        134

      • Removing and Installing Door Handle

        135

      • Removing Bearing Bracket

        137

      • Removing and Installing Door Lock

        139

      • Assembly Overview — Side Impact Protection

        141

      • Door Inner Seals

        141

      • Removing and Installing Door Inner Seal

        142

      • Removing and Installing Door Outer Seal

        143

      • Rear Door (Variant)

        147

      • Tools

        147

      • Assembly Overview — Rear Door

        148

      • Assembly Overview — Door Hinges

        148

      • Removing and Installing Door

        150

      • Adjusting Door

        152

      • Assembly Overview — Assembly Carrier

        154

      • Removing and Installing Assembly Carrier

        155

      • Assembly Overview — Door Handle and Door Lock

        160

      • Removing and Installing Housing

        161

      • Removing and Installing Door Handle

        161

      • Removing and Installing Bearing Bracket

        164

      • Removing and Installing Door Lock

        165

      • Door Inner Seals

        165

      • Removing and Installing Door Inner Seal

        166

      • Removing and Installing Door Outer Seal

        167

  • Sunroof

    171

    • Sliding/Tilting Sunroof with Glass Panel (Meritor)

      171

      • Tools

        171

      • Function

        171

      • Assembly Overview — Sliding/Tilting Sunroof with Glass Panel

        173

      • Removing and Installing Bellows

        174

      • Removing and Installing Sliding/Tilting Sunroof Glass Panel

        176

      • Adjusting Height of Sliding/Tilting Sunroof Glass Panel

        177

      • Adjusting Panel Seal

        178

      • Renewing Panel Seal

        179

      • Removing and Installing Wind Deflector

        179

      • Removing and Installing Sliding Headliner

        180

    • Removing and Installing Sliding/Tilting Sunroof Glass Panel Drive

      181

      • Adjusting Drive for Sliding/Tilting Sunroof Glass Panel (0 Position)

        182

      • Removing and Installing Sliding/Tilting Sunroof Glass Panel Automatic Preselection Switch

        182

      • Checking Parallel Running

        182

      • Adjusting Parallel Running

        183

      • Assembly Overview — Carrier Unit

        184

    • Removing and Installing Carrier Unit

      184

    • Operating Without Current

      187

    • Removing and Installing Guide Plate

      187

    • Removing and Installing Guide Plate

      188

    • Cleaning Water Drain Hoses

      189

    • Panorama Sliding Sunroof (Arvin-Meritor)

      192

    • Tools

      192

    • Function

      192

    • Establishing Reference Points of Panorama Sliding Roof

      193

    • Assembly Overview — Panorama Sliding Roof

      194

    • Removing and Installing Front Glass Panel

      195

    • Removing and Installing Rear Glass Panel

      197

    • Adjusting Height of Front and Rear Glass Panel

      198

    • Renewing Seals for Rear Glass Panel

      200

    • Renewing Outer Seal

      201

    • Renewing Inner Seal

      203

    • Removing and Installing Wind Deflector

      203

    • Removing and Installing Wind Deflector Bracket

      205

    • Removing and Installing Preselector for Glass Panel and Sun Blind

      206

    • Removing and Installing Sliding Sunroof Motor

      206

    • Removing and Installing Sun Blind Motor

      208

    • Removing and Installing Sun Blind

      209

    • Assembly Overview — Assembly Frame

      213

    • Installing and Removing Motor Plate and Sun Blind Cable

      214

    • Removing and Installing Assembly Frame

      217

    • Removing and Installing Rear Part

      219

    • Removing and Installing Front Motor Plate

      222

    • Removing and Installing Tilting Mechanism and Front Glass Panel Cable

      225

    • Maintenance and Care

      227

    • Operating Without Current

      227

    • Sun Blind

      228

    • Cleaning Water Drain Hoses

      229

Volkswagen Golf Variant 2007 Workshop Manual

Volkswagen Golf Variant 2007 Workshop Manual (374 pages)

Running gear, axles, steering

Brand: Volkswagen
|
Category: Automobile
|
Size: 12.43 MB

Table of Contents

  • Golf Variant 2007 ➤ , Jetta

    8

  • Technical Data

    9

  • General Information

    11

  • Front Suspension

    12

  • Repairing Front Suspension

    13

  • Raising Wheel Suspension to Unladen Position

    14

  • Subframe, Anti-Roll Bar, Suspension Links

    17

  • Assembly Overview: Front Left Vehicle Level Sender G78

    22

  • Repairing Thread in Longitudinal Member

    23

  • Fixing Position of Subframe and Brackets

    24

  • Lowering Subframe

    25

  • Removing and Installing Subframe Without Steering Box

    29

  • Removing and Installing Subframe with Steering Box

    31

  • Repairing Subframe (Front-Wheel Drive)

    36

  • Repairing Subframe (Four-Wheel Drive)

    39

  • Checking Swivel Joint

    43

  • Removing and Installing Swivel Joint

    44

  • Removing and Installing Suspension Link with Mounting Bracket

    46

  • Renewing Bonded Rubber Bush for Suspension Link

    54

  • Renewing Mounting Bracket with Suspension Link Bush

    56

  • Removing and Installing Anti-Roll Bar

    58

  • Assembly Overview: Wheel Bearing

    63

  • Removing and Installing Wheel Bearing Unit

    64

  • Removing and Installing Wheel Bearing Housing

    66

  • Assembly Overview: Suspension Strut

    70

  • Removing and Installing Suspension Strut

    71

  • Repairing Suspension Strut

    76

  • Removing and Installing Drive Shafts

    78

  • Loosening and Tightening 12-Point Flange Bolt Securing Drive Shaft

    79

  • Removing and Installing Drive Shaft with Constant Velocity Joint

    80

  • Removing and Installing Left Drive Shaft with (Push-On) Constant Velocity Slip Joint

    82

  • Removing and Installing Right Drive Shaft with (Push-On) Constant Velocity Slip Joint

    86

  • Removing and Installing Drive Shafts with Triple Roller Joint Aar2600I

    89

  • Removing and Installing Drive Shafts with Triple Roller Joint Aar3300I

    91

  • Removing and Installing Intermediate Shaft

    93

  • Repairing Drive Shaft — Overview of Drive Shafts

    95

  • Heat Shields for Drive Shafts

    97

  • Assembly Overview: Drive Shaft with VL90 or VL100 Constant Velocity Joint

    98

  • Dismantling and Assembling Drive Shaft with VL90 or VL100 Constant Velocity Joint

    100

  • Checking Outer Constant Velocity Joint

    104

  • Checking Inner Constant Velocity Joint

    105

  • Assembly Overview: Drive Shaft with VL107 Constant Velocity Joint (Bolt-On)

    108

  • Dismantling and Assembling Drive Shaft with VL107 Constant Velocity Joint

    110

  • Golf Variant 2007 ➤ , Jetta

    111

  • Repairing Intermediate Shaft

    115

  • Assembly Overview: Drive Shaft with VL107 Constant Velocity Slip Joint (Push-On)

    117

  • 10.1 Dismantling and Assembling Drive Shaft with VL107 (Push-On) Constant Velocity Slip Joint

    118

  • Checking Outer Constant Velocity Joint

    120

  • Assembly Overview: Drive Shaft with Triple Roller Joint Aar2600I

    122

  • Dismantling and Assembling Drive Shaft with Triple Roller Joint Aar2600I

    123

  • Assembly Overview: Drive Shaft with Triple Roller Joint Aar3300I

    128

  • Dismantling and Assembling Drive Shaft with Triple Roller Joint Aar3300I

    130

  • Appraisal of Accident Vehicles

    135

  • Repairing Rear Suspension (Front-Wheel Drive)

    136

  • Rear Axle in Unladen Position

    137

  • Assembly Overview: Subframe, Transverse Link, Track Rod (Front-Wheel Drive)

    140

  • Removing and Installing Rear Axle

    142

  • Vehicle Level Sender for Vehicles with Automatic Headlight Range Control

    147

  • Removing and Installing Upper Transverse Link

    148

  • Removing and Installing Lower Transverse Link

    150

  • Removing and Installing Track Rod

    151

  • Assembly Overview: Wheel Bearing Housing, Trailing Arm (Front-Wheel Drive)

    155

  • Removing and Installing Wheel Bearing Housing

    156

  • Renewing Bonded Rubber Bush for Wheel Bearing Housing

    160

  • Removing and Installing Wheel Bearing/Wheel Hub Unit

    163

  • Removing and Installing Trailing Arm with Mounting Bracket

    165

  • Repairing Trailing Arm

    169

  • Assembly Overview: Shock Absorber, Coil Spring

    172

  • Removing and Installing Shock Absorbers

    174

  • Repairing Shock Absorber

    176

  • Assembly Overview: Anti-Roll Bar

    178

  • Bluemotion (Front-Wheel Drive)

    181

  • Removing and Installing Shield

    182

  • Repairing Rear Suspension (Four-Wheel Drive)

    184

  • Rear Axle in Unladen Position

    186

  • Assembly Overview: Subframe, Final Drive (Four-Wheel Drive)

    188

  • Repairing Subframe

    194

  • Assembly Overview: Transverse Link, Track Rod (Four-Wheel Drive)

    201

  • Overview — Rear Left Vehicle Level Sender G76

    204

  • Removing and Installing Upper Transverse Link

    205

  • Removing and Installing Lower Transverse Link

    207

  • Removing and Installing Track Rod

    209

  • Assembly Overview: Wheel Bearing Housing, Trailing Arm (Four-Wheel Drive)

    212

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Volkswagen Golf Variant 2007 Workshop Manual

Volkswagen Golf Variant 2007 Workshop Manual (319 pages)

Brand: Volkswagen
|
Category: Automobile
|
Size: 12.2 MB

Table of Contents

  • Table of Contents

    3

  • Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta

    8

  • Interior Equipment

    9

    • Interior Mirror

      9

    • Tools

      9

    • Automatic Anti-Dazzle Interior Mirror

      9

    • Removing and Installing Interior Mirror with Rain Sensor

      9

    • Bonding on Retaining Plate for Interior Mirror with Rain Sensor

      10

    • Removing and Installing Interior Mirror in Vehicles with Adaptive Cruise Control

      11

    • Removing and Installing Interior Mirror

      13

    • Bonding on Retaining Plate for Interior Mirror Without Rain Sensor

      13

    • Compartments, Covers and Trims

      15

    • Tools

      15

    • Removing and Installing Basic Version Centre Console (Jetta 2010 ▸, Golf Variant 2010 ▸)

      19

    • Removing and Installing Highline Centre Console (Jetta 2005 ▸, Golf Variant 2007 ▸)

      24

    • Removing and Installing Highline Centre Console (Jetta 2010 ▸, Golf Variant 2010 ▸)

      33

    • Removing and Installing Mounting Bracket for Centre Console (Jetta 2005 ▸, Golf Variant 2007 ▸)

      43

    • Removing and Installing Mounting Bracket for Centre Console and Mounting Bracket for Footwell Trim (Jetta 2010 ▸, Golf Variant 2010 ▸)

      44

    • Removing and Installing Cup Holder in Highline Centre Console

      45

    • Repairing Cup Holder in Centre Console, Highline

      46

    • Removing and Installing Dash Panel Centre Vents (Vehicles with no Climatronic) (Jetta 2005 ▸, Golf Variant 2007 ▸)

      51

    • Removing and Installing Dash Panel Centre Vents (Vehicles with Climatronic) (Jetta 2005 ▸, Golf Variant 2007 ▸)

      53

    • Removing and Installing Centre Storage Compartment in Dash Panel (Jetta 2010 ▸, Golf Variant 2010 ▸)

      56

    • Removing and Installing Dash Panel Centre Vents (Jetta 2010 ▸, Golf Variant 2010 ▸)

      57

    • Removing and Installing Dash Panel Middle Trim (Jetta 2005 ▸, Golf Variant 2007 ▸)

      59

    • Removing and Installing Dash Panel Middle Trim (Jetta 2010 ▸, Golf Variant 2010 ▸)

      60

    • Removing and Installing Air Conditioner Controls Unit / Heater Controls Unit Trim (Jetta 2010 ▸, Golf Variant 2010 ▸)

      61

    • Removing and Installing Dash Panel End Trims

      62

    • Removing and Installing Steering Column Trim

      63

    • Removing and Installing Left Trim Panel on Driver Side with no Storage Compartment

      64

    • Removing and Installing Left Trim Panel on Driver Side with Storage Compartment

      66

    • Removing and Installing Right Trim Panel on Driver Side

      68

    • Removing and Installing Glove Compartment

      70

    • Removing and Installing Glove Compartment Lock Cylinder

      74

    • Removing and Installing Footwell Cover on Driver Side

      75

    • Removing and Installing Centre Cover (Jetta 2005 ▸, Golf Variant 2007 ▸)

      80

    • Removing and Installing Centre Cover (Jetta 2010 ▸, Golf Variant 2010 ▸)

      80

    • Removing and Installing Sun Visor

      81

    • Sill Panel Mouldings

      85

    • Removing and Installing Sill Panel Mouldings

      85

    • Removing and Installing Wheel Housing Liner (Saloon)

      86

    • Removing and Installing Wheel Housing Liner (Variant)

      87

    • Grab Handles

      89

    • Removing and Installing Roof Grab Handles

      89

    • Removing and Installing Roof Grab Handle Bracket

      90

    • Net Partition

      92

    • Removing and Installing Net Partition

      92

    • Removing and Installing Net Partition Mountings

      93

    • Removing and Installing Net Partition Bracket on Vehicles with no Panorama Sliding Roof

      94

    • Removing and Installing Net Partition Bracket on Vehicles with Panorama Sliding Roof

      95

  • Passenger Protection

    96

    • Seat Belts

      96

    • General Safety Regulations When Working on Airbag, Belt Tensioner and Battery Isolator Units (Pyrotechnic Components)

      97

    • Special Instructions for Belt Tensioners

      98

    • Storage, Transportation and Disposal of Airbag, Belt Tensioner and Battery Isolator Units (Pyrotechnic Components)

      98

    • Assembly Overview — Front Seat Belts

      99

    • Removing and Installing Front Seat Belts

      99

    • Removing and Installing Front Belt Height Adjuster

      101

    • Removing and Installing Front Belt Buckle

      102

    • Assembly Overview — Rear Outer Seat Belts (Saloon)

      104

    • Removing and Installing Rear Outer Seat Belts (Saloon)

      104

    • Assembly Overview — Rear Outer Seat Belts (Variant)

      106

    • Removing and Installing Rear Outer Seat Belts (Variant)

      106

    • Assembly Overview — Rear Centre 3-Point Seat Belt

      108

    • Removing and Installing Rear Centre 3-Point Seat Belt

      108

    • Removing and Installing Middle Rear Seat Lap Belt

      109

    • Removing and Installing Rear Double Belt Buckle

      110

    • Inspecting Seat Belts

      112

    • Points to Check

      112

    • Checking Child Seat Anchors (ISOFIX) after an Accident

      116

    • Points to Check

      116

    • Removing and Installing Child Seat Anchorages in Rear Shelf

      116

    • Airbag

      117

    • Overview of Locations — Airbag Systems

      117

    • General Safety Regulations When Working on Airbag, Belt Tensioner and Battery Isolator Units (Pyrotechnic Components)

      119

    • Special Instructions for Driver and Front Passenger Airbag

      120

    • Special Instructions for Curtain Airbag Modules

      120

    • Storage, Transportation and Disposal of Airbag, Belt Tensioner and Battery Isolator Units (Pyrotechnic Components)

      120

    • Deactivating the Airbag

      120

    • Renewing Airbag Units Following an Accident

      121

    • Removing and Installing Airbag Control Unit J234

      122

    • Removing and Installing Airbag Unit on Driver Side (Jetta 2005 ▸, Golf Variant 2007 ▸)

      124

    • Removing and Installing Airbag Unit on Driver Side (Jetta 2010 ▸, Golf Variant 2010 ▸)

      128

    • Removing and Installing Airbag Coil Connector and Return Spring with Slip Ring F138

      131

    • Removing and Installing Key Operated Switch to Deactivate Front Passenger Airbag E224

      131

    • Removing and Installing Knee Airbag (Jetta 2010 ▸, Golf Variant 2010 ▸)

      132

      • Drive Vehicles

        134

      • Drive Vehicles

        136

    • Removing and Installing Return Spring with Slip Ring

      138

    • Removing and Installing Front Passenger Airbag Unit

      138

    • Removing and Installing Side Airbags on Driver and Front Passenger Sides

      143

    • Removing and Installing Rear Side-Airbag

      144

    • Removing and Installing Curtain Airbag on Driver and Passenger Side (Saloon)

      146

    • Removing and Installing Curtain Airbag on Driver and Passenger Side (Variant)

      148

    • Removing and Installing Seat Occupied Sensor, Front Passenger Side G128

      150

    • Adapting Components

      155

    • Seat Occupied Recognition (USA)

      156

    • Safety Precautions for When Working on Seat Occupied Recognition

      156

    • Procedure for Seat Belt Tensioner after an Accident and /Or Triggering of Airbag

      156

    • Assembly Overview — Seat Occupied Recognition (USA)

      157

    • Parts Repair Kit for Seat Occupied Recognition

      157

    • Removing and Installing Repair Kit for Seat Occupied Recognition on Vehicles with Manually Adjusted Seats

      158

    • Removing and Installing Repair Kit for Seat Occupied Recognition on Vehicles with Electrically Adjusted Seats

      167

    • Importers Reporting Obligation

      176

    • Crash Sensors

      178

    • Tools

      178

    • Removing and Installing Side Airbag Crash Sensor on Driver Side G179

      181

    • Variant 2010 ▸)

      181

    • Removing and Installing Side Airbag Crash Sensor on Front Passenger Side G180 (Jetta 2010 ▸, Golf Variant 2010 ▸)

      183

    • Removing and Installing Crash Sensors in Rear Wheel Housing (Saloon)

      183

    • Removing and Installing Crash Sensors in Rear Wheel Housing (Variant)

      185

Volkswagen Golf Variant 2007 Workshop Manual

Volkswagen Golf Variant 2007 Workshop Manual (246 pages)

Brand: Volkswagen
|
Category: Automobile
|
Size: 9.73 MB

Table of Contents

  • Table of Contents

    3

  • Technical Data

    5

    • Gearbox Identification

      5

    • Location on Gearbox

      5

    • Identification Code, Assembly Allocation and Capacities

      5

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

      5

    • Overview — Power Transmission

      9

    • Calculating Overall Gear Ratio „I

      11

    • General Repair Notes

      12

    • Contact Corrosion

      12

    • Special Tools

      12

    • Components

      12

  • Clutch

    16

    • Fault Finding, Power Transmission

      16

    • Repairing Clutch Mechanism

      17

    • Overview

      17

    • Assembly Overview — Pedal Cluster

      18

    • Removing and Installing Over-Centre Spring

      19

    • Removing and Installing Clutch Pedal

      23

    • Removing and Installing Mounting Bracket

      27

    • Removing and Installing Master Cylinder

      33

    • Removing and Installing Clutch Position Sender G476

      34

    • Assembly Overview — Hydraulics (LHD)

      38

    • Assembly Overview — Hydraulics (RHD)

      40

    • Bleeding Clutch System

      41

    • Repairing Clutch Release Mechanism

      43

    • Removing Pipe/Hose Line and Bleeder from and Installing on Slave Cylinder

      44

    • Removing and Installing Slave Cylinder with Release Bearing

      44

    • Removing and Installing Pipe/Hose Line or Plastic Line

      45

    • Renewing Input Shaft Seal

      47

    • Repairing Clutch — Vehicles with Turbo Diesel Engine

      49

    • Determining Clutch Manufacturer

      49

    • Removing and Installing „Sachs» Clutch

      51

    • Repairing „Sachs» Clutch

      54

    • Removing and Installing „Luk» Clutch

      54

    • Repairing „Luk» Clutch

      57

    • Repairing Clutch — Vehicles with Petrol Engine

      58

    • Repairing Clutch

      59

    • Removing and Installing Clutch

      59

  • Controls, Housing

    63

    • Repairing Selector Mechanism

      63

    • Installation Position of Selector Mechanism

      63

    • Overview of Selector Mechanism

      64

    • Removing and Installing Gear Knob and Frame

      66

    • Removing and Installing Gaiter with Gear Knob and Noise Insulation

      66

    • Repairing Gear Lever and Selector Housing (through 10.06)

      68

    • Repairing Gear Lever and Selector Housing (from 11.06)

      70

    • Assembly Overview — Removing and Installing Selector Cables

      75

    • Plastic Relay Lever

      79

    • Removing and Installing Selector Mechanism

      82

    • Removing and Installing Gear Selector Cable and Gate Selector Cable

      84

    • Adjusting Selector Mechanism

      86

    • Functional Check

      88

    • Removing and Installing Gearbox in Vehicles with Turbo Diesel Engine

      89

    • Removing Gearbox

      89

    • Transporting Gearbox

      100

    • Installing Gearbox

      101

    • Specified Torques

      108

    • Removing and Installing Gearbox, Vehicles with Petrol Engine

      110

    • Removing Gearbox

      110

    • Transporting Gearbox

      120

    • Installing Gearbox

      121

    • Specified Torques

      128

    • Checking Gearbox Oil

      130

    • Dismantling and Assembling Gearbox

      132

    • Overview — Rear Final Drive

      132

    • Assembly Overview

      133

    • Removing and Installing Gearbox Housing and Selector Mechanism

      134

    • Removing and Installing Input Shaft, Output Shafts, Differential and Selector Rods

      136

    • Assembly Order, Gearbox »Without« Retaining Ring a for Input Shaft Sealing Cover

      138

    • Assembly Order, Gearbox »With« Retaining Ring a for Input Shaft Sealing Cover

      149

    • Repairing Gearbox Housing

      161

    • Repairing Clutch Housing

      171

    • Repairing Selector Unit

      176

    • Renewing Oil Seal for Selector Shaft

      177

    • Repairing Selector Forks

      179

Volkswagen Golf Variant 2007 Maintenance Manual

Volkswagen Golf Variant 2007 Maintenance Manual (214 pages)

Brand: Volkswagen
|
Category: Automobile
|
Size: 5.89 MB

Table of Contents

  • Table of Contents

    3

  • 1 Engine List

    5

    • In Litres Number of Cylinders 4

      8

    • Engine List

      9

  • 2 Service Work

    10

    • Service Tables for «Rest of World» Markets

      10

    • Spark Plugs

      13

    • Service Scope for North American and Canadian Markets

      15

    • Service Scope for «Rest of World» Markets up to Model Year 2007

      21

    • Page

      21

    • Service Scope for «Rest of World» Markets from Model Year 2008

      29

      • Oil Change Service

        29

      • Interval Service

        31

      • Inspection Service

        32

    • Service Intervals for «Rest of World» Markets

      39

    • Service Intervals for North American and Canadian Markets

      39

    • Information on Longlife Service or Time or Distance Dependent Service

      40

  • 3 General

    41

    • Tow Starting/Towing for North American and Canadian Markets

      41

    • Raising Vehicle with Lifting Platform and Trolley Jack

      45

    • Sticker

      45

    • Delivery Inspection

      46

    • Connecting Vehicle Diagnostic Tester

      47

    • Vehicle Identification Number

      50

    • Vehicle Data Sticker

      50

    • Countries with Elevated Sulphur Content in Diesel Fuel

      51

    • Severe Operating Conditions

      51

    • Engine Code and Engine Number

      52

    • Engine Oils for North American and Canadian Markets

      52

    • Engine Oils for «Rest of World» Markets

      52

    • RME Fuel -Biodiesel- for Vehicles up to 05.2006

      53

    • Type Plate

      53

  • 4 Descriptions of Work

    55

    • Removable Towing Bracket: Check

      57

    • Swivel Joints: Visual Check

      59

    • Driving Light Assist and Cornering Light: Check Function

      59

    • Automatic Gearbox: Check ATF Level, 09G Gearbox

      60

    • Battery: Check Battery Terminal Clamps for Secure Seating

      60

    • Battery: Check Using Battery Tester with Printer VAS 5097A

      62

    • Front Passenger Front Airbag: Check Activation / Deactivation for Vehicles Without Seat

      62

    • Occupied Recognition

      62

    • Checking Tyres: Condition, Wear Pattern, Inflation Pressure, Tread Depth

      63

    • General Notes

      65

    • Brake and Clutch System: Change Brake Fluid

      71

    • Brake Fluid Level: Check

      75

    • Brake System: Perform Visual Check for Leaks and Damage

      76

    • Front and Rear Brake Pads/Linings: Check Thickness

      76

    • Front Brake Pads

      77

    • Checking Diesel Particulate Filter

      78

    • 6-Speed Dual Clutch Gearbox (DSG) 02E: Change Oil and Filter

      78

    • Electric Windows: Check Positioning (Open and Close Functions)

      79

    • Vehicle System Test: Perform Test

      79

    • Protective Bellows: Visual Check

      80

    • Renewing Rubber Buffers for Engine Cover

      81

    • Haldex Coupling (Jetta 4Motion): Change Oil

      82

    • Poly V-Belt: Adjust Tension on Engines Without Automatic Tensioning Roller

      85

    • Poly V-Belt: Check Condition

      86

    • Dash Panel Insert: Adapt Menu Language Versions

      87

    • Compass: Set Compass Zone and Calibrate Compass (for North American, Canadian and Mexican Markets)

      88

    • Multifunction Steering Wheel

      88

    • Cooling System: Check Frost Protection and Coolant Level

      92

    • Fuel Filter: Renew

      95

    • Air Filter: Clean Housing and Renew Filter Element

      99

    • Memory Seat: Perform Initialisation

      108

    • Engine and Components in Engine Compartment (from above and Below): Perform Visual Check for Leaks and Damage

      109

    • Engine Cover -Top-: Removing and Installing

      109

    • Removing and Installing Engine Compartment Cover -Bottom- (Noise Insulation)

      120

    • Engine Oil Level: Check

      121

    • Engine Oil: Drain or Extract; Renew Oil Filter and Replenish Engine Oil

      121

    • Checking Breakdown Set

      137

    • Panorama Sliding Roof: Check Function, Clean Guide Rails if Necessary and Grease with Special Grease, Clean Wind Deflector

      138

    • Performing Road Test (Driving Behaviour, Noises, Air Conditioner Etc.)

      139

    • Wheel Securing Bolts: Tighten to Prescribed Torque Setting

      140

    • Reading Radio Code with Fault Reader

      143

    • Radio/Navigation System: Activate Anti-Theft Coding

      144

    • Tyre Pressure Monitoring: Perform Basic Setting

      148

    • Renewing Tyre Pressure Sensors

      150

    • Dust and Pollen Filter: Clean Housing and Renew Filter Element

      150

    • Headlight Adjustment: Check

      151

    • Adjusting Headlights

      155

    • Service Interval Display: Reset

      157

    • Service Interval Display: Recode (for «Rest of World» Markets)

      158

    • Service Interval Display: Recode at Delivery Inspection

      160

    • Markets)

      160

    • Service Interval Display: Recode at First Oil Change Service (for North American and Canadian Markets)

      162

    • Sunroof: Check Function, Clean and Grease Guide Rails

      164

    • Window Wash/Wipe System and Headlight Washer System: Check Function

      164

    • Wiper Blades: Check Park Position

      169

    • Wiper Blade Protection: Remove

      170

    • Track Rod Ends: Check Play, Security and Boots

      173

    • Auxiliary Heater: Set Weekday in Menu of Combi-Instrument

      173

    • Door Arrester: Grease

      174

    • Transportation Mode: Switch off

      174

    • Transportation Devices: Remove Blocking Pieces from Front Axle Springs

      176

    • Underbody Sealant: Perform Visual Check for Damage to Underbody Sealant, Underbody Panels, Routing of Lines and Plugs

      176

    • Clock and Date: Set to Correct Time

      177

    • Camshaft Drive Toothed Belt: Check (TDI Unit Injector Engines)

      178

    • Toothed Belt and Toothed Belt Tensioning Roller: Renew (TDI Engines)

      178

    • Camshaft Drive Toothed Belt: Renew (2.0 L FSI and TFSI)

      179

    • Camshaft Drive Toothed Belt: Check (4-Cylinder Petrol Engines 1.4 L and 1.6 L)

      179

    • Spark Plugs: Renew

      179

Volkswagen Golf Variant 2007 Repair Manual

Volkswagen Golf Variant 2007 Repair Manual (224 pages)

Brand: Volkswagen
|
Category: Automobile
|
Size: 15.42 MB

Table of Contents

  • Table of Contents

    3

  • General, Technical Data

    5

    • Transmission Identification

      5

    • Overview — Transmission

      6

    • Engine Codes, Engine Allocation

      7

    • Capacities

      8

    • Safety Precautions

      9

    • General Safety Precautions

      9

    • Safety Precautions When Working on Vehicles with Start/Stop System

      9

    • Safety Precautions During Road Test with Testing Equipment

      10

    • Tow Starting and Towing Notes

      11

    • General Repair Information

      12

    • Tools

      12

    • Transmission

      12

    • Working with Vehicle Diagnostic Testers

      17

  • Clutch

    19

    • Dual Clutch, Removing and Installing, through Transmission Production Date 05/2011

      19

    • Overview — Dual Clutch, through Transmission Production Date 05/2011

      19

    • Dual Clutch, Removing, through Transmission Production Date 05/2011

      21

    • K 1″ and «K 2» Clutch Engaging Bearing Position, Adjusting, Transmission Production Date through 05/2011

      24

    • Dual Clutch, Installing, Transmission Production Date through 05/2011

      37

    • Dual Clutch, Removing and Installing, from Transmission Production Date 06/2011

      44

    • Overview — Dual Clutch, Transmission Production Date from 06/2011

      44

    • Dual Clutch, Removing, Transmission Production Date from 06/2011

      46

    • K 1″ and «K 2» Clutch Engaging Bearing Position, Adjusting, Transmission Production Date from 06/2011

      49

    • Dual Clutch, Installing, Transmission Production Date from 06/2011

      62

    • Clutch-Side Seals, Removing and Installing

      67

    • Special Tools

      70

  • Controls, Housing

    74

    • Transmission Fluid, Replacing

      74

    • Selector Mechanism

      78

    • Selector Mechanism Overview, through 02/2009

      78

    • Selector Lever Cable, Removing and Installing, through 02/2009

      80

    • Selector Mechanism Overview, from 03/2009

      88

    • Selector Mechanism, Removing and Installing, Vehicles from 03/2009

      89

    • Selector Lever Cable, Checking

      97

    • Selector Lever Cable, Adjusting

      98

    • Selector Lever, Emergency Release

      100

    • Selector Lever Handle, Removing and Installing

      100

    • Button in Handle, Moving into Installation Position

      103

    • Selector Mechanism, Checking

      105

    • DSG Transmission Mechatronic J743

      107

    • DSG Transmission Mechatronic J743 Safety Precautions

      107

    • Overview — Mechatronic

      108

    • DSG Transmission Mechatronic J743 , Removing with Transmission Installed

      109

    • DSG Transmission Mechatronic J743 , Moving into «Removal Position» by Hand

      119

    • DSG Transmission Mechatronic J743 , Moving into Re- Moval Position by Hand

      119

    • DSG Transmission Mechatronic J743 , Installing

      123

    • Overview — Shift Forks with Mechatronic Removed

      129

    • Transmission, Removing and Installing, Jetta from MY 2005, Golf Wagon from MY 2007 and Golf Wagon from MY 2010

      131

    • Transmissions with Different Output Shafts

      131

    • Transmission, Removing, Vehicles with 1.4L/90 Kw TFSI Engine and 1.4L/118 Kw TSI Engine

      131

    • Transmission, Removing, Vehicles with 1.6L/75 Kw MPI Engine

      139

    • Transmission, Removing, Vehicles with 1.9L 77 Kw TDI PD Engine

      147

    • Transmission, Removing, Vehicles with 1.6L/77 Kw TDI CR Engine

      154

    • Transmission, Installing, Jetta from MY 2005, Golf Wagon from MY 2007, Golf Wagon from

      161

    • Transmission to Engine» Tightening Specifications and Subframe Mount Information

      165

    • Transmission, Removing and Installing, Jetta from MY 2011

      170

    • Transmission, Removing, Jetta 2011 with 1.4L/90 Kw TFSI Engine and 1.4L/118 Kw TSI Engine

      170

    • Transmission, Removing, Jetta 2011 with 1.6L/77 Kw TDI CR Engine

      179

    • Transmission, Installing, Jetta MY 2011

      187

    • Tightening Specifications

      192

    • Transmission, Transporting and Securing to Assembly Stand

      195

    • Special Tools

      198

Volkswagen Golf Variant 2007 Service Manual

Volkswagen Golf Variant 2007 Service Manual (206 pages)

6-speed manual gearbox 02S

Brand: Volkswagen
|
Category: Automobile
|
Size: 11.23 MB

Table of Contents

  • Table of Contents

    3

  • Technical Data

    5

    • Gearbox Identification

      5

    • Location on Gearbox

      5

    • Identification Code, Assembly Allocation and Capacities

      5

    • Overview — Power Transmission

      9

    • Calculating Overall Gear Ratio «I

      11

    • General Repair Notes

      12

    • Components

      12

  • Clutch

    16

    • Fault Finding, Power Transmission

      16

    • Repairing Clutch Mechanism

      17

    • Overview

      17

    • Assembly Overview — Pedal Cluster

      18

    • Removing and Installing Over-Centre Spring

      19

    • Removing and Installing Clutch Pedal

      24

    • Removing and Installing Mounting Bracket

      29

    • Removing and Installing Master Cylinder

      35

    • Removing and Installing Clutch Position Sender G476

      37

    • Assembly Overview — Hydraulics (LHD Vehicles)

      41

    • Assembly Overview — Hydraulics (RHD Vehicles)

      43

    • Removing and Installing Slave Cylinder

      44

    • Bleeding Clutch System

      46

    • Repairing Clutch Release Mechanism

      48

    • Repairing Clutch, in Conjunction with Dual-Mass Flywheel

      50

    • Determining Clutch Manufacturer

      50

    • Removing and Installing Sachs Clutch

      52

    • Repairing Sachs Clutch

      54

    • Removing and Installing Luk Clutch

      54

    • Repairing Luk Clutch

      57

    • Repairing Clutch, in Conjunction with One-Piece Flywheel

      58

  • Controls, Housing

    61

    • Fault Finding, Power Transmission

      61

    • Repairing Selector Mechanism

      62

    • Installation Position of Selector Mechanism

      62

    • Overview of Selector Mechanism

      63

    • Removing and Installing Gear Knob and Frame

      65

    • Removing and Installing Gaiter with Gear Knob and Noise Insulation

      65

    • Repairing Gear Lever and Selector Housing (through 10.06)

      67

    • Repairing Gear Lever and Selector Housing (from 11.06)

      69

    • Assembly Overview — Removing and Installing Selector Cables

      74

    • Plastic Relay Lever

      77

    • Removing and Installing Selector Mechanism

      79

    • Removing and Installing Gear Selector Cable and Gate Selector Cable

      82

    • Adjusting Selector Mechanism

      84

    • Functional Check

      86

    • Removing and Installing Gearbox

      88

    • Removing Gearbox

      89

    • Transporting Gearbox

      95

    • Installing Gearbox

      96

    • Specified Torques

      100

    • Checking and Topping up Gear Oil

      103

    • Preparation

      103

    • Draining Gear Oil

      104

    • Filling with Gear Oil

      105

    • Dismantling and Assembling Gearbox

      106

    • Overview — Gearbox

      106

    • Assembly Overview

      107

    • Removing and Installing Cover for Gearbox Housing and 5Th and 6Th Gear

      108

    • Removing and Installing Gearbox Housing and Shift Mechanism

      111

    • Removing and Installing Input Shaft, Output Shaft, Differential and Selector Forks

      112

    • Gear

      113

    • Assembly Sequence — Dismantling and Assembling Gearbox Completely

      119

    • Repairing Gearbox Housing and Clutch Housing

      136

    • Repairing Gearbox Housing Cover

      142

    • Repairing Selector Unit

      146

    • Dismantling and Assembling Selector Forks

      149

Volkswagen Golf Variant 2007 Workshop Manual

Volkswagen Golf Variant 2007 Workshop Manual (180 pages)

Brand: Volkswagen
|
Category: Automobile
|
Size: 1.72 MB

Table of Contents
  • Table of Contents

    5

  • Technical Data

    7

  • 1 General Notes on Air Conditioning Systems

    7

    • Introduction

      7

    • Additional Information

      7

    • Basics of Air Conditioning

      8

    • Vapour Pressure Table for Refrigerant R134A

      9

    • Refrigerant R134A

      10

    • Characteristics of Refrigerant R134A

      11

    • Refrigerant Machine Oil

      13

    • Comfort

      15

    • How Air Conditioning Works

      15

    • General Safety

      16

    • Safety Precautions for When Working on Vehicles with Air Conditioning and When Handling

      19

      • Refrigerant R134A

        19

    • Basics for Working on Refrigerant Circuit

      20

  • 2 General Information on Refrigerant Circuit

    23

    • Refrigerant Circuit Components

      23

    • Design of Refrigerant Circuit

      31

    • Evacuation and Charging Valves for Quick-Release Couplings of Air Conditioner Service Station

      31

      • On Refrigerant Circuit

        31

    • Switch and Sender in Refrigerant Circuit and Related Connections

      33

    • Electrical Components Not Installed in Refrigerant Circuit

      36

    • Pressures and Temperatures in the Refrigerant Circuit

      38

    • Refrigerant Circuit with Expansion Valve

      38

    • Refrigerant Circuit with Restrictor and Reservoir

      40

    • Test and Measurement Work that Can be Performed Using a Pressure Gauge

      42

    • Air Conditioner Service and Recycling Equipment

      43

    • Notes to Repairs on Refrigerant Circuit

      44

  • 3 Statutory Texts and Instructions

    45

    • Statutes and Regulations

      45

    • Recycling and Refuse Law

      50

    • Converting R12 Refrigerant Circuits to R134A Refrigerant Circuits and Repairing Them (Retrofitting)

      51

    • Maintaining Records on Refrigerant

      51

  • 4 Refrigerant Circuit

    52

    • Important Repair Notes on Air Conditioning

      52

    • Retrofitting Refrigerant Circuit from R12 Refrigerant to R134A Refrigerant

      52

  • 5 Working with the Air Conditioner Service Station

    53

    • Important Notes for Working with the Air Conditioner Service Station

      54

    • Connecting Air Conditioner Service Station for Measuring and Checking

      54

    • Draining Refrigerant Circuit Using Air Conditioner Service Station

      55

    • Evacuating Refrigerant Circuit Using Air Conditioner Service Station

      56

    • Charging Refrigerant Circuit Using Air Conditioner Service Station

      57

    • Bringing Air Conditioning System into Service after Charging

      58

    • Charging Container in Air Conditioner Service Station with Refrigerant

      59

    • Draining Air Conditioner Service Station

      59

  • 6 Detecting Leaks in Refrigerant Circuit

    61

    • Leak Detection in Refrigerant Circuit Using Compressed Air or Nitrogen

      62

    • Searching for Leaks in Refrigerant Circuits Using Leak Detector V.A.G 1796

      64

    • Detecting Leaks in Refrigerant Circuit Using Leak Detecting System VAS 6196 or Leak Detecting

      65

      • System VAS 6201 or a Later Model

        65

Volkswagen Golf Variant 2007 Workshop Manual

Volkswagen Golf Variant 2007 Workshop Manual (116 pages)

Brand: Volkswagen
|
Category: Automobile
|
Size: 4.24 MB

Table of Contents

  • Table of Contents

    3

  • Technical Data

    5

    • Suggestions and Criticism, General Repair Notes

      5

    • Suggestions and Criticism of this Workshop Manual

      5

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

      5

    • General Repair Notes

      6

    • Gearbox

      6

    • Torque Converter

      6

    • Atf

      6

    • Automatic Gearbox Control Unit J217 with Fuzzy Logic

      6

    • Control Units in Vehicle

      6

    • Information on «09G Gearbox

      6

    • Tools

      6

    • Gearbox

      7

    • Gaskets, Seals and Oil

      8

    • Nuts and Bolts

      8

    • Electrical Components

      8

    • Guided Fault Finding, Vehicle Self-Diagnosis and Testing

      9

    • Gearbox Identification

      10

    • Gearbox Codes

      10

    • Capacities

      11

    • Planetary Gearbox and Final Drive

      11

    • Codes, Gearbox Allocation, Ratios

      12

  • Torque Converter

    13

    • Identification of Torque Converter

      13

    • Draining Torque Converter

      13

    • Removing and Installing Torque Converter Oil Seal

      13

    • Installing Torque Converter

      14

  • Controls, Housing

    15

    • Connecting «Tester

      15

    • Connecting Vehicle Diagnosis, Testing and Information System VAS 5051

      15

    • Electrical and Electronic Components and Their Locations

      17

    • Multifunction Switch F125

      22

    • Removing Multifunction Switch F125

      22

    • Installing Multifunction Switch F125

      23

    • Adjusting Multifunction Switch F125

      24

    • Selector Mechanism up to 02.2009

      26

    • Overview of Selector Mechanism up to 02.2009

      26

    • Removing and Installing Selector Mechanism with Selector Lever up to 02.2009

      27

    • Removing and Installing Selector Lever Cable up to 02.2009

      27

    • Checking Selector Lever Cable

      34

    • Adjusting Selector Lever Cable

      34

    • Emergency Release of Selector Lever

      35

    • Removing and Installing Knob

      36

    • Checking Selector Mechanism

      37

    • Selector Mechanism from 03.2009 Onwards

      39

    • Overview of Selector Mechanism in Vehicles from 03.2009 Onwards

      39

    • Onwards

      39

    • Emergency Release of Selector Lever

      41

    • Removing and Installing Gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008

      42

    • Removing Gearbox, Vehicles with 1.6 L — 75 Kw and 2.0 L — 110 Kw (FSI) Engines

      42

    • Installing Gearbox, Vehicles with 1.6 L — 75 Kw and 2.0 L — 110 Kw (FSI) Engines

      49

    • Removing Gearbox, Vehicles with 2.5 L, 110 Kw Engine

      49

    • Installing Gearbox, Vehicles with 2.5 L, 110 Kw Engine

      57

    • Torque Settings, Gearbox to Engine

      58

    • Removing and Installing Gearbox, Jetta 2011

      61

    • Removing Gearbox, Jetta 2011 with 2.0 L — 85 Kw Engine

      61

    • Installing Gearbox, Jetta 2011 with 2.0 L — 85 Kw Engine

      67

    • Removing Gearbox, Jetta 2011 with 2.5 L — 125 Kw Engine

      67

    • Installing Gearbox, Jetta 2011 with 2.5 L — 125 Kw Engine

      76

    • Torque Settings, Gearbox to Engine

      76

    • Transporting Gearbox

      79

    • ATF Cooler

      80

    • Assembly Overview — ATF Cooler

      80

    • Checking ATF Level and Topping up

      81

    • Checking ATF Level

      82

    • Topping up ATF

      83

    • Draining and Filling ATF

      84

Volkswagen Golf Variant 2007 Workshop Manual

Volkswagen Golf Variant 2007 Workshop Manual (123 pages)

Electrical System, General Information

Brand: Volkswagen
|
Category: Automobile
|
Size: 1.6 MB

Table of Contents

  • Table of Contents

    3

  • Starter, Current Supply, CCS

    5

    • Battery a

      5

    • Fundamentals for Batteries a

      5

    • Types of Battery

      5

    • Warning Notices and Safety Regulations

      6

    • Battery Terminal Connection

      8

    • Checking Battery a

      9

    • Testing Different Battery Types

      9

    • Visual Check

      10

    • Test of Colour Display of Magic Eye

      11

    • Battery Tester with Printer VAS 5097 a

      12

    • Battery Tester with Printer VAS 6161

      17

    • Midtronics MCR340V Battery Tester (Only for Usa/Canada)

      23

    • Current Draw Test

      27

    • Checking No-Load Voltage of Battery a (Stock and Stored Vehicles)

      28

    • Charging Battery a

      30

    • Battery Charger VAS 5095 a

      30

    • Battery Charger VAS 5900

      35

    • Trickle Charging

      46

    • Battery Charger VAS 5903

      47

    • Battery Charger VAS 5906

      59

    • Midtronics INC 940 Battery Charger (Only for Usa/Canada)

      61

    • Solar Panel VAS 6102 a

      66

    • Totally Discharged Batteries a

      67

    • Cruise Control System (CCS)

      69

    • Activating and Deactivating Cruise Control System (CCS)

      69

  • Gauges, Instruments

    70

  • Windscreen Wash/Wipe System

    71

    • Washer Fluid Line Hose Couplings

      71

    • Windscreen and Rear Window Washer System

      71

    • Headlight Washer System

      72

    • Hose Repair

      73

    • General Description

      73

    • Repairing Smooth Pipe

      73

    • Repairing Corrugated Pipe

      73

    • Distinguishing Features of Jointless Wiper Blades

      75

  • Lights, Bulbs, Switches — Exterior

    76

    • Operation and Safety Notes for Gas Discharge Bulbs

      76

  • Lights, Bulbs, Switches — Interior

    79

    • Socket U5

      79

    • Removing and Installing 12 V Socket U5

      79

    • Removing and Installing Socket Illumination Bulb L42

      79

    • Cigarette Lighter U1

      80

    • General Description

      80

    • Assembly Overview

      81

    • Removing and Installing Cigarette Lighter Socket

      82

    • Removing and Installing Cigarette Lighter Illumination Bulb L28

      84

  • Wiring

    86

    • Vehicle Diagnosis, Testing and Information System VAS 5051B

      86

    • Connecting Vehicle Diagnosis, Testing and Information System VAS 5051B

      86

    • Connecting Vehicle Diagnostic Tester Bora Model Year 1998 to 2003

      87

    • Repairs to Wiring Harnesses and Connectors

      89

    • Wiring Harness Repair Set

      89

    • Tool Descriptions

      90

    • General Notes Concerning Repairs to Vehicle Electrical System

      94

    • Repairs to Wiring Harnesses

      95

    • Repairs to Contact Housings and Connectors

      105

    • Releasing and Dismantling Contact Housings

      109

    • Contact Surface Cleaning Set VAS 6410

      115

    • Using the Contact Surface Cleaning Set VAS 6410

      115

    • Cleaning Battery Terminals

      118

    • Renewing Lambda Probe

      121

    • Renewing LSF Lambda Probe (4-Pin)

      121

    • Renewing LSU Lambda Probe (6-Pin)

      122

    • Types of Protective Tube on Uniform Lambda Probes

      123

Volkswagen Golf Variant 2007 Workshop Manual

Volkswagen Golf Variant 2007 Workshop Manual (127 pages)

7-speed dual clutch gearbox 0AM

Brand: Volkswagen
|
Category: Automobile
|
Size: 10.89 MB

Table of Contents

  • Table of Contents

    3

  • Technical Data

    5

    • Gearbox Identification

      5

    • Code, Engine Allocation

      6

    • Capacities

      7

    • General Repair Notes

      8

    • Tools

      8

    • Gearbox

      8

    • Oil

      10

    • Working with Vehicle Diagnostic Testers

      10

  • Clutch

    12

    • Removing and Installing the Dual Clutch

      12

    • Removing Dual Clutch

      12

    • Adjusting Position of Engagement Bearings «K 1 and K 2

      16

    • Installing Dual Clutch

      26

  • Controls, Housing

    34

    • Renewing Gear Oil

      34

    • Selector Mechanism

      37

    • Overview — Selector Mechanism in Vehicles up to 02.2009

      37

    • Removing and Installing Selector Lever Cable — Vehicles up to 02.2009

      38

    • Overview of Selector Mechanism — Vehicles from 03.2009 Onwards

      45

    • Removing and Installing Selector Mechanism with Selector Lever and Selector Lever Cable

      46

    • Vehicles from 03.2009 Onwards

      46

    • Checking Selector Lever Cable

      47

    • Adjusting Selector Lever Cable

      47

    • Emergency Release of Selector Lever

      50

    • Removing and Installing Selector Lever Handle

      50

    • Checking Selector Mechanism

      52

    • Mechatronic Unit for Dual Clutch Gearbox J743

      54

    • Safety Note on Mechatronic Unit for Dual Clutch Gearbox J743

      54

    • Overview — Mechatronic Unit

      55

    • Removing Mechatronic Unit for Dual Clutch Gearbox J743 with Gearbox Installed

      56

    • Moving Mechatronic Unit for Dual Clutch Gearbox J743 into «Removal Position» by Hand

      66

    • Installing Mechatronic Unit for Dual Clutch Gearbox J743

      69

    • View of Selector Forks with Mechatronic Unit Removed

      76

    • Removing and Installing Gearbox

      77

    • Information about Gearboxes with Different Output Shafts

      77

    • Removing Gearbox, Vehicles with 1.4 L/90 Kw TFSI Engine and 1.4 L/118 Kw TSI Engine

      78

    • Removing Gearbox, Vehicles with 1.6 L/75 Kw MPI Engine

      85

    • Removing Gearbox — Vehicles with 1.9 L/77 Kw TDI PD Engine

      94

    • Removing Gearbox — Vehicles with 1.6 L/77 Kw TDI CR Engine

      101

    • Installing Gearbox

      108

    • Torque Settings «Gearbox to Engine» and Notes on Assembly Mounting

      111

    • Transporting Gearbox and Securing to Assembly Stand

      115

  • Gears, Shafts

    117

    • Currently, no Repairs Can be Made to Gears and Shafts

      117

  • Renewing Oil Seal for Right Stub Shaft

    118

  • Final Drive — Front Differential

    118

    • Oil Seals

      118

  • Renewing Oil Seal for Left Stub Shaft

    120

  • Renewing Seal for Right Flange Shaft

    122

  • Renewing Oil Seal for Left Flange Shaft

    124

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Руководство на английском языке по техническому обслуживанию и ремонту автомобилей Volkswagen Golf и Volkswagen Jetta 1984-1992 годов выпуска с бензиновыми двигателями.

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Руководство на английском языке по техническому обслуживанию и ремонту автомобилей Volkswagen Golf и Volkswagen Vento 1992-1998 годов выпуска с бензиновыми и дизельными двигателями.

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Руководство на английском языке по техническому обслуживанию и ремонту автомобилей Volkswagen Bora и Volkswagen Golf 1998-2000 годов выпуска с бензиновыми и дизельными двигателями.

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Service Manual VW Golf/Golf GTI 1999-2005 г.

Руководство на английском языке по техническому обслуживанию и ремонту автомобилей Volkswagen Golf/Golf GTI/Jetta 1999-2005 годов выпуска с бензиновыми и дизельными двигателями.

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Volkswagen Golf Variant 2007 Service Manual

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Service

Workshop Manual

Golf Variant 2007 ➤

Golf Variant 2010 ➤

Jetta 2005 ➤

6-speed manual gearbox 02S

Edition 07.2009

Service Department. Technical Information

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Summary of Contents for Volkswagen Golf Variant 2007

  • Page 1
    Service Workshop Manual Golf Variant 2007 ➤ Golf Variant 2010 ➤ Jetta 2005 ➤ 6-speed manual gearbox 02S Edition 07.2009 Service Department. Technical Information…
  • Page 2
    In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R007520…

  • Page 3: Table Of Contents

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Contents 00 — Technical data ……….. .

  • Page 4
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Draining gear oil …………100 Filling with gear oil .

  • Page 5: Technical Data

    Technical data Gearbox identification The 6-speed manual gearbox 02S is installed in the Jetta 2005 ▸, in the Golf Variant 2007 ▸ and in the Golf Variant 2010 ▸ in con‐ junction with a 4-cylinder engine. Allocation ⇒ page 1…

  • Page 6
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Manual gearbox 6-speed 02S Identification code Engine 1.9 l — 74 kW 1.4 l — 103 kW 1.9 l — 74 kW…
  • Page 7
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Manual gearbox 6-speed 02S Identification code Capacity of manual gearbox (gear‐ 2.1 l 2.1 l 2.1 l box completely dismantled) Capacity of manual gearbox 1.9 l…
  • Page 8
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Manual gearbox 6-speed 02S Identification code • The following data can be found in the ⇒ Electronic parts catalogue “ETKA” .

  • Page 9: Overview — Power Transmission

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Overview — power transmission Designation -Arrows- indicate direction of travel. 1 — Engine 2 — Clutch 3 — Manual gearbox…

  • Page 10
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 I — 1st gear II — 2nd gear III — 3rd gear IV — 4th gear V — 5th gear…

  • Page 11: Calculating Overall Gear Ratio «I

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Calculating overall gear ratio “i” Example: 6th gear Final drive Drive gear ZG 1 = 45 ZA 1 = 18…

  • Page 12: General Repair Notes

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 General repair notes To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential.

  • Page 13
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 4.1.3 Locking devices ♦ Do not overstretch retaining rings. ♦ Always renew retaining rings which have been damaged or overstretched.
  • Page 14
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 4.1.6 Shims ♦ Measure shims at several points with a micrometer. The var‐ ious thicknesses make it possible to achieve the exact shim thickness required.
  • Page 15
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Ensure that the pressure plate does not cant: loosen and tight‐ en bolts diagonally and in several gradual stages.

  • Page 16: Clutch

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 30 – Clutch Fault finding, power transmission – Refer to ⇒ Fault finding, power transmission; Rep. Gr. 30 ; Complaints about clutch and clutch mechanism and ⇒ Fault finding, power transmission;…

  • Page 17: Repairing Clutch Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Repairing clutch mechanism Overview Note Before disconnecting battery, obtain code for radio units having anti-theft coding. ♦ With ignition switched off, disconnect battery earth strap ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting ♦…

  • Page 18: Assembly Overview — Pedal Cluster

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Assembly overview — pedal cluster 1 — Bulkhead ❑ With support for mount‐ ing bracket 2 — Seal ❑ Always renew ❑…

  • Page 19: Removing And Installing Over-Centre Spring

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ❑ Qty. 3 ❑ For mounting bracket on bulkhead ❑ Always renew 16 — Hexagon nut, 25 Nm ❑ Always renew 17 — Stop ❑…

  • Page 20
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – With ignition switched off, disconnect battery earth strap ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .
  • Page 21
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket. – To do this, remove lock washers -A- for damping.
  • Page 22
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-. Note The clutch pedal remains hooked to operating rod of master cyl‐…
  • Page 23
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Some cars have damping -arrow- on the clutch pedal mounting bracket. – Return it to installation position. Vehicles without knee airbag The crash bar -1- in front of clutch pedal -2- may be secured in different ways.

  • Page 24: Removing And Installing Clutch Pedal

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 2.3.3 Specified torques Component Clutch pedal to mounting bracket ♦ Renew self-locking nuts Crash bar to steering column mounting bracket (attachment with 2 bolts)

  • Page 25
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Continuation for all – Push driver seat as far back as possible and put steering wheel in highest position. – Remove trim and cover below trim on drive side ⇒ General body repairs, interior;…
  • Page 26
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – If fitted, remove damping -arrow- from lower area of clutch pedal mounting bracket. – To do this, remove lock washers -A- for damping.
  • Page 27
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-. – Swing clutch pedal down slightly and remove over-centre spring -4- from mounting bracket.
  • Page 28
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Insert over-centre spring -2- in mounting bracket from above while holding end of spring with assembly tool -T10178- in in‐…

  • Page 29: Removing And Installing Mounting Bracket

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 The crash bar -1- in front of clutch pedal -2- may be secured in different ways. Attachment with 2 bolts –…

  • Page 30
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Hose clamps to 25 mm Ø -3094- ♦ Hose clip pliers -VAS 6362- ♦ Sealing tool -T10249- 2.5.1 Removing –…
  • Page 31
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Continuation for all Note During the following work, ensure that no brake fluid lands on ♦ longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.
  • Page 32
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Remove bracket for knee airbag together with crash bar ⇒ Interior equipment; Rep. Gr. 69 ; Airbag; Removing and in‐…
  • Page 33
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – To do this, remove lock washers -A- for damping. – Pull off damping. – Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in -direction of arrow-.
  • Page 34
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Some cars have damping -arrow- on the clutch pedal mounting bracket. Note Renew self-locking nuts. ♦ Renew hose clips. ♦…

  • Page 35: Removing And Installing Master Cylinder

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Push pipe/hose line or plastic line -1- with seal -2- onto con‐ nection of master cylinder -4- until securing clip -3- engages audibly.

  • Page 36
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Release retainer for master cylinder operating rod using pliers -T10005- . – Insert spacer -A- between clutch pedal and stop and press clutch pedal to spacer.

  • Page 37: Removing And Installing Clutch Position Sender G476

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Insert spacer -A- between clutch pedal and stop and press clutch pedal to spacer. ♦ Length of spacer = about 40 mm (e.g.

  • Page 38
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Remove complete air filter housing if it is near battery ⇒ Rep. Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep.
  • Page 39
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Clamp off supply hose to master cylinder using hose clamp to 25 mm ∅ -3094- . – Release securing clip -2- with a screwdriver or a pointed object and pull out of master cylinder to stop.
  • Page 40
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 If the pipe/hose line was removed – Push pipe/hose line -1- or plastic line with seal -2- onto con‐ nection of master cylinder -4- until securing clip -3- engages audibly.

  • Page 41: Assembly Overview — Hydraulics (Lhd Vehicles)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Assembly overview — hydraulics (LHD vehicles) 1 — Brake fluid reservoir 2 — Spring-type clip 3 — Supply hose ❑ Rubber ❑…

  • Page 42
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 15 — Hexagon bolt, 20 Nm 16 — Bleeder valve ❑ Bleeding clutch system ⇒ page 42 17 — Dust cap…

  • Page 43: Assembly Overview — Hydraulics (Rhd Vehicles)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Assembly overview — hydraulics (RHD vehicles) 1 — Brake fluid reservoir 2 — Seal ❑ For plastic supply hose ❑ The seals must be loca‐…

  • Page 44: Removing And Installing Slave Cylinder

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ❑ Insert with brake fluid ❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 38 ❑ Allocation ⇒ Electronic parts catalogue “ETKA”…

  • Page 45
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – With ignition switched off, disconnect battery earth strap ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .

  • Page 46: Bleeding Clutch System

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 2.10.2 Installing Install in the reverse order of removal, observing the following: – Install slave cylinder and tighten bolts -arrows B- to specified torque.

  • Page 47
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Brake filling and bleeding equipment -V.A.G 1869- Note Prefilling system is not necessary! Specifications for brake fluid ⇒ Brake systems; Rep. Gr. 47 ;…

  • Page 48: Repairing Clutch Release Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Repairing clutch release mechanism Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- 1 — Gearbox 2 — Ball stud, 25 Nm ❑…

  • Page 49
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ❑ Renew noisy bearings ❑ Removing from and inserting in clutch release lever ⇒ page 45 ❑ Lubricate contact surfaces of release lever with MoS 2 grease.

  • Page 50: Repairing Clutch, In Conjunction With Dual-Mass Flywheel

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Repairing clutch, in conjunction with dual-mass flywheel Special tools and workshop equipment required ♦ Counterhold -3067- ♦ Centring mandrel -3190 A- ♦…

  • Page 51
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Some notches -arrows- are located in lower region of sump be‐ tween engine -A- and gearbox -B-. – Check outer contour of flywheel through these notches.

  • Page 52: Removing And Installing Sachs Clutch

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Rounded outer contour -arrows 1- and a circumferential crease -arrow 2- = LuK clutch = -B- – Removing and installing LuK clutch ⇒…

  • Page 53
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Checking ends of diaphragm spring • Wear to half the thickness of the diaphragm spring -arrows- is permitted. Checking spring connections and riveted connections –…

  • Page 54: Repairing Sachs Clutch

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Repairing Sachs clutch 1 — Dual-mass flywheel ❑ Removing and installing ⇒ Rep. Gr. 13 ❑ Ensure that centring pins fit tightly ❑…

  • Page 55
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Note Renew pressure plate and clutch plate together only. Select ♦ clutch plate and pressure plate according to engine code and ⇒…
  • Page 56
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Checking position of adjusting mechanism with new pressure plates only • Both edges -A- of the adjuster ring must be located between the two notches -arrows B-.

  • Page 57: Repairing Luk Clutch

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Repairing LuK clutch 1 — Dual-mass flywheel ❑ Removing and installing ⇒ Rep. Gr. 13 ❑ Ensure that centring pins fit tightly ❑…

  • Page 58: Repairing Clutch, In Conjunction With One-Piece Flywheel

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Repairing clutch, in conjunction with one-piece flywheel Special tools and workshop equipment required ♦ Counterhold -3067- ♦ Centring mandrel -3190 A- ♦…

  • Page 59
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 1 — Flywheel ❑ Removing and installing ⇒ Rep. Gr. 13 ❑ Ensure that centring pins fit tightly ❑ Keep contact surface for clutch lining free of grooves, oil and grease.
  • Page 60
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Checking ends of diaphragm spring • Wear up to half the thickness of the diaphragm spring is per‐ mitted. Checking spring connections and riveted connections –…

  • Page 61: Controls, Housing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 34 – Controls, housing Fault finding, power transmission – Refer to ⇒ Fault finding, power transmission; Rep. Gr. 30 ;…

  • Page 62: Repairing Selector Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Repairing selector mechanism Installation position of selector mechanism Arrow -A- Gear selection movement Arrow -B- Gate selection movement A — Gear selector cable…

  • Page 63: Overview Of Selector Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Overview of selector mechanism Note Note radio code for vehicles with coded radio. ♦ Before working on selector mechanism in engine compartment, disconnect earth strap from battery ⇒ Elec‐…

  • Page 64
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Hose clip pliers -V.A.G 1275- ♦ Torque wrench -V.A.G 1331- Rep. Gr.34 — Controls, housing…

  • Page 65: Removing And Installing Gear Knob And Frame

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Removing and installing gear knob and frame 1 — Emblem ❑ Can be carefully levered off gear knob of plastic…

  • Page 66
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Pull gaiter with frame for centre console upwards, inside out over gear knob. – Open clamp -arrow- and pull off gear knob together with gaiter.

  • Page 67: Repairing Gear Lever And Selector Housing (Through 10.06)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Repairing gear lever and selector housing (through 10.06) Note Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .

  • Page 68
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 25 — Securing clip ❑ Always renew 26 — Hexagon nut ❑ M8: 25 Nm ❑ M6: 8 Nm ❑ Qty. 4 27 — Bearing bush ❑…

  • Page 69: Repairing Gear Lever And Selector Housing (From 11.06)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Repairing gear lever and selector housing (from 11.06) Note Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .

  • Page 70
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 14 — Bush 15 — Gear lever guide 16 — Hexagon nut ❑ M8: 25 Nm ❑ M6: 8 Nm ❑…
  • Page 71
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Lift upper end -A- of compression spring over tab of gate se‐ lector lever. – Use screwdriver to press catches -arrows- of ball socket to‐…
  • Page 72
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Slacken ends -A- and -B- by turning both round to right. • Ends -A- and -B- must point in opposite directions.
  • Page 73
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Move gate selector lever back to stop (opposite from mounting holes for gear and gate selector cable) -arrow 1-.

  • Page 74: Assembly Overview — Removing And Installing Selector Cables

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Assembly overview — removing and installing selector cables Note Lubricate bearing points and sliding surfaces with grease -G 000 450 02- .

  • Page 75
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 9 — Spacer 10 — Cable end-piece ❑ For gate selector cable to relay lever ❑ After installing, adjust selector mechanism ⇒…
  • Page 76
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Allocation of cable end-pieces The holes in the cable end-pieces have different diameters. Cable end-piece for Dimension “a” 1 — Gear selector cable to gearbox selector lever 8.5 mm…

  • Page 77: Plastic Relay Lever

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Fitting position of cable tie for cables – Wind cable tie -arrow- around the selector cables in a figure eight and secure them as shown in figure.

  • Page 78
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Relay lever with clip -arrow 1- – Pull clip -arrow 1- off and remove relay lever together with ca‐ ble end-piece.

  • Page 79: Removing And Installing Selector Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Levering gate selector cable end-piece off plastic relay lever • Relay lever has been removed. – Insert a flat-blade screwdriver -A- between bush -B- and relay lever.

  • Page 80
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Torque wrench -V.A.G 1331- ♦ Grease -G 000 450 02- – First check whether a coded radio is fitted. If so, obtain anti- theft code.
  • Page 81
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Releasing cable end-piece from gate selector cable – Pull locking mechanism forward to stop in -direction of arrow 1- and then lock by turning to left in -direction of arrow 2-.

  • Page 82: Removing And Installing Gear Selector Cable And Gate Selector Cable

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Clip -A- holds cables and heat shield together in position. – Install cable support bracket on gearbox and tighten bolts to specified torques ⇒…

  • Page 83
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Bend open tabs -arrows- of selector mechanism cover using a screwdriver and remove cover. – Remove gasket. – Pull off securing clips -2 and 3-. (Securing clips -1 and 4- have been discontinued.) Lever gear selector cable off gear lever…

  • Page 84: Adjusting Selector Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Secure gear selector cable and gate selector cable to selector housing using securing clips -2 and 3-. – Press gear selector cable onto gear lever and gate selector cable onto gate selector lever in selector housing.

  • Page 85
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Remove complete air filter housing if bracket -A- to secure gear selector cable and gate selector cable are not accessible ⇒…

  • Page 86: Functional Check

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Check that gate and selector cables -B- are inserted, free of tension, into locking devices -A-. – Now turn locking mechanisms on gear selector cable and gate selector cable end pieces clockwise to stop -direction of arrow 1-.

  • Page 87
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – If it continues to be difficult to engage a gear after repeated attempts, repeat adjustment procedure of selector mechanism ⇒…

  • Page 88: Removing And Installing Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Removing and installing gearbox Special tools and workshop equipment required ♦ Vehicles with turbo diesel engines and vehicles with 2.0l — 110 kW petrol engines ♦…

  • Page 89: Removing Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Adjustment plate -3282/39- ♦ Engine and gearbox jack — V.A.G 1383A- ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦…

  • Page 90
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Pull gear selector cable from pin. Metal relay lever – Remove securing clip -arrow 2- for gate selector cable from relay lever -B-.
  • Page 91
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Pull connector -arrow 1- off reversing light switch -F4- . – Now remove connector -arrow 2- and wire -arrow 3- from starter.
  • Page 92
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Now attach hook -10 — 222 A /2- at rear left of engine -arrow-. – Then connect hook -10 — 222 A /2- using adapter -10 — 222 A / 16- .
  • Page 93
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Remove pendulum support. First remove bolt -arrow A- and then bolts -B- and -C-. – Remove hexagon bolts -arrows- for left assembly mounting from gearbox mounting.
  • Page 94
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it. – Remove exhaust system strut -1-, if present, from gearbox -arrow-.

  • Page 95: Transporting Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Press gearbox off dowel sleeves and carefully swing towards subframe. – Turn gearbox downwards in vicinity of differential. – Have a second mechanic push engine forwards slightly.

  • Page 96: Installing Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Adjust support beam on sliding piece using locking pin -arrow-. Number of holes visible = 5. – Lift gearbox using workshop crane and gearbox lifting tackle -3336- .

  • Page 97
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 The clutch plate must slide easily to and fro on the input shaft. To install gearbox “02S”, set up gearbox support -3282- with ad‐…
  • Page 98
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque ⇒ page 96 – Align engine and gearbox in installation position using both spindles of support bracket -10-222A- .
  • Page 99
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Install pendulum support with new bolts -arrows A-, -B- and -C- ⇒ Running gear, axles, steering ; Rep. Gr. 40 ; Repairing front suspension .

  • Page 100: Specified Torques

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Install gearbox selector lever -A-. – Tighten hexagon nut -arrow 4- to specified torque ⇒ Item 18 (page 71) –…

  • Page 101
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Gearbox to 2.0 l/100 kW petrol engine Item Bolt Quantity M12 x 65 M12 x 150 ♦ Additionally, start‐ er to gearbox M12 x 165 ♦…
  • Page 102
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Gearbox mounting to body – Renew bolts. – Screw in all bolts hand-tight. – Tighten bolts to specified torque. Bolts -arrows- 60 Nm + 90°…

  • Page 103: Checking And Topping Up Gear Oil

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Checking and topping up gear oil It is not possible to check the gear oil level by unscrewing the oil filler plug.

  • Page 104: Draining Gear Oil

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Clean gearbox. Caution To drain gear oil, a pivot pin for the selector forks in the gearbox must be removed.

  • Page 105: Filling With Gear Oil

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Filling with gear oil Top up oil in container to 1.9 litres. Gearbox oil specification ⇒ Electronic parts catalogue “ETKA” .

  • Page 106: Dismantling And Assembling Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Dismantling and assembling gearbox Overview — gearbox 1 — 1st gear 2 — 2nd gear 3 — 3rd gear 4 — 4th gear…

  • Page 107: Assembly Overview

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Assembly overview Assembly sequence — Removing and installing cover for gearbox housing and 5th and 6th gear ⇒ page 109 Assembly sequence — Dismantling and assembling gearbox com‐…

  • Page 108: Removing And Installing Cover For Gearbox Housing And 5Th And 6Th Gear

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Removing and installing cover for gearbox housing and 5th and 6th gear 1 — Gearbox housing ❑ Pull off together with 5th and 6th gears ⇒…

  • Page 109
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ❑ Allocation of bolts ⇒ page 106 ❑ To gearbox date 20 08 6: 40 Nm and 180° further ❑ From gearbox date 21 08 6: 80 Nm and then turn 90° further ❑…
  • Page 110
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 20 — Wave spring washer ❑ From gearbox date 26 05 8 ❑ Allocate according to ⇒ Electronic parts catalogue “ETKA”…

  • Page 111: Removing And Installing Gearbox Housing And Shift Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Removing and installing gearbox housing and shift mechanism 1 — Countersunk bolt, 25 Nm 2 — Flange shaft with compres‐…

  • Page 112: Removing And Installing Input Shaft, Output Shaft, Differential And Selector Forks

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Removing and installing input shaft, output shaft, differential and selector forks 1 — Differential ❑ Dismantling and assem‐ bling ⇒ page 193 2 — Seal ❑…

  • Page 113: Gear

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Assembly sequence — Removing and in‐ stalling cover for gearbox housing and 5th and 6th gear Note Follow the working procedure described below if only the 5th ♦…

  • Page 114
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Support bridge -30-211A- ♦ Thrust piece -32 — 111- ♦ Thrust piece from assembly tool -T10030/4- ♦ Tube -VW 416 B- ♦…
  • Page 115
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Support device -T10323- ♦ Assembly tool -3253/7- ♦ Thrust piece -VW 433- ♦ Thrust plate -40 — 105- ♦ Torque wrench -V.A.G 1332- 5.6.1…
  • Page 116
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 • Bearings of input shaft and output shaft must not be damaged when 5th and 6th gears are removed and installed.
  • Page 117
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Check whether puller hooks -T10040/2A- can be inserted cor‐ rectly under 5th gear wheel. Puller hooks -T10040/2A- cannot be inserted correctly.
  • Page 118
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Pull off gear wheel for 6th gear with inner race of cylindrical roller bearing for output shaft. A — Two arm puller , e.g. -Kukko 20/10-…

  • Page 119: Assembly Sequence — Dismantling And Assembling Gearbox Completely

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Set threaded insert -T10309/3- in half shell . – Now fit second half shell -T10309/1- and set tube -T10309/2- over assembly.

  • Page 120
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Special tools and workshop equipment required ♦ Support plate -VW 309- ♦ Gearbox support -VW 353- ♦ Drift -VW 295- ♦…
  • Page 121
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Support bridge -30-211A- ♦ Thrust piece -32 — 111- ♦ Thrust piece from assembly tool -T10030/4- ♦ Tube -VW 416 B- ♦…
  • Page 122
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Support device -T10323- ♦ Assembly tool -3253/7- ♦ Thrust piece -VW 433- ♦ Torque wrench -V.A.G 1332- ♦ Mounting -2 Kukko 18/1- (Qty. 2) ♦…
  • Page 123
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 • Bearings of input shaft and output shaft must not be damaged when 5th and 6th gears are removed and installed.
  • Page 124
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Remove selector fork for 5th and 6th gears as follows: – Cover openings with a cloth. – Engage 5th gear -arrows 1- and -2-.
  • Page 125
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Now remove 3rd bolt -arrow- for reverse shaft support bracket. – Remove selector shaft with selector mechanism cover, placing selector shaft in neutral position.
  • Page 126
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Remove bolts -A- from clutch housing side for securing clutch housing to gearbox housing. Note Do not remove nuts -B- for output shaft bearing support.
  • Page 127
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Remove selector forks -A- together with selector plates. – Unbolt reverse gear selector mechanism -B-. – Remove nuts -B- for output shaft bearing support.
  • Page 128
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Insert input shaft -1- and output shaft -2- together. – Tighten nuts for output shaft bearing support to specified tor‐…
  • Page 129
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Screw M8 x 100 mm studs -A- into reverse shaft support so that shaft is aligned after gearbox housing is fitted.
  • Page 130
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Install selector shaft with selector shaft cover plate as follows: – Place selector plates in neutral. – Apply sealant -AMV 188 200 03- evenly to sealing surface of selector mechanism cover.
  • Page 131
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Checking 5th gear synchro-ring and 6th gear synchro-ring – Before installing synchromeshed gears and synchro-rings for 5th and 6th gear, press synchro-rings onto cones of synchro‐…
  • Page 132
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Drive on synchro-hub for 5th and 6th gear. Note When driving on, ensure that synchro-ring moves freely. – Heat inner race of cylindrical roller bearing for 6th gear syn‐…
  • Page 133
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Installation position of gear wheel for 6th gear: Groove -B- faces away from sleeve -A-. “Or” groove -arrow 1- near shoulder -arrow 2- faces away from sleeve -A- see previous figure).
  • Page 134
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – To tighten securing bolts -A-, engage 2 gears -arrows 1- through -3-. – Install selector forks for 5th and 6th gears.
  • Page 135
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Adjusting 5th and 6th gear from gearbox manufacture date 12 06 6 – Engage 5th gear. – Loosen bolt -1-.

  • Page 136: Repairing Gearbox Housing And Clutch Housing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Repairing gearbox housing and clutch housing Special tools and workshop equipment required ♦ Drift -VW 295- ♦ Adapter -VW 295 A- ♦…

  • Page 137
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Puller -VW 228 B- (is not required for this gearbox) ♦ Drift -VW 222 A- (not re‐ quired with this gearbox) ♦…
  • Page 138
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 1 — Gearbox housing ❑ If renewed: adjust input shaft and differential ⇒ page 192 2 — Needle bearing ❑ For output shaft ❑…
  • Page 139
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ❑ Remove guide sleeve to change oil seal ❑ If O-ring is damaged, renew guide sleeve and O-ring together 13 — Socket head bolt, 20 Nm ❑…
  • Page 140
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Driving needle bearing in to stop – Secure needle bearing in gearbox housing at three points (120° offset) using a punch.
  • Page 141
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Pulling in sleeve – Clean sleeve seat in gearbox. – Screw spindle -A- of assembly device -3066- into threaded piece of differential.

  • Page 142: Repairing Gearbox Housing Cover

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Repairing gearbox housing cover Special tools and workshop equipment required ♦ Pressure plate -VW 401- ♦ Pressure plate -VW 402- ♦…

  • Page 143
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 1 — Cylindrical roller bearing ❑ For output shaft ❑ Do not interchange with cylindrical roller bearing for input shaft ❑…
  • Page 144
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Pulling cylindrical roller bearing out of gearbox housing cover A — Internal puller, 30 … 37 mm , e.g. -Kukko 21/5- B — Counter support , e.g.
  • Page 145
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Secure cylindrical roller bearing in gearbox housing cover by pe‐ ening -arrows-. 7. Repairing gearbox housing cover…

  • Page 146: Repairing Selector Unit

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Repairing selector unit Special tools and workshop equipment required ♦ Tube -T10203- ♦ Tube -VW 423- ♦ Torque wrench -V.A.G 1331-…

  • Page 147
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 1 — Selector unit ❑ Consists of selector shaft and selector shaft cover ❑ Components cannot be separated from each other 2 — -Schalter für Rückfahr‐…
  • Page 148
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Removing angled rod -A- from selector shaft cover – Remove outer part of angled rod. – Then carefully lever out angled rod using a screwdriver.

  • Page 149: Dismantling And Assembling Selector Forks

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Dismantling and assembling selector forks Special tools and workshop equipment required ♦ Pressure plate -VW 402- ♦ Thrust piece -3290/1- ♦…

  • Page 150
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Drift -10 — 508- ♦ Clamp -2070- Note It is not necessary to dismantle the selector fork group ( ⇒…
  • Page 151
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 1 — Selector segment for 5th and 6th gears ❑ Identification ⇒ page 148 ❑ After lock washer is in‐…
  • Page 152
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Identifying selector segments Dimension -a- 1 — 1st and 2nd gear selector segments = 11.4 mm 2 — 3rd and 4th gear selector segments = 7.7 mm 3 — 5th and 6th gear selector segments = 12.1 mm…
  • Page 153
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Pressing inner race -A- of angular contact ball bearing into outer race Inner race must engage in outer race. Pulling angular contact ball bearing into selector fork to stop Depression in thrust piece -3290/1- faces ball bearing.

  • Page 154: Gears, Shafts

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 35 – Gears, shafts Input shaft Dismantling and assembling input shaft Special tools and workshop equipment required ♦ Press tool -VW 407- ♦…

  • Page 155
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Drift sleeve -41 — 501- ♦ Thrust pad -VW 447 i- ♦ Drift sleeve -30 — 100- ♦ Thrust pad -VW 510- ♦…
  • Page 156
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 1 — Clutch housing 2 — Tapered roller bearing outer race ❑ Pressing out ⇒ page 154 ❑ Pressing in ⇒…
  • Page 157
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 16 — Wave spring washer ❑ From gearbox date 26 05 8 ❑ Allocate according to ⇒ Electronic parts catalogue “ETKA”…
  • Page 158
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Pressing out tapered roller bearing outer race Pressing in tapered roller bearing outer race Pressing off tapered roller bearing inner race…
  • Page 159
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Pressing off gear wheel for 4th gear with tapered roller bearing and sleeve Pressing off gear wheel for 3rd gear…
  • Page 160
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Pressing on tapered roller bearing inner race Pressing on sleeve for needle bearing Pressing out tapered roller bearing outer race Pressing in tapered roller bearing outer race –…
  • Page 161
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Deeper notches in both sides of locking collar for 5th and 6th gears -arrows- from gearbox date 12 06 6…

  • Page 162: Adjusting Input Shaft

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Installing springs with bent ends -A- The modified springs are installed on both sides. – Spring are installed only in conjunction with locking pieces which are hollow on the inner side.

  • Page 163
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Special tools and workshop equipment required ♦ Universal dial gauge brack‐ et -VW 387- ♦ End dimension plate — VW 385/17- ♦…
  • Page 164
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Press tapered roller bearing outer race into gearbox housing to stop. – Press tapered roller bearing outer race without shim into gear‐…
  • Page 165
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Table of shims Bearing play Shim Measured value (mm) Thickness (mm) 0.671…0.699 0.650 0.700…0.724 0.675 0.725…0.749 0.700 0.750…0.774 0.725 0.775…0.799 0.750…
  • Page 166
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Set gearbox housing in place and tighten hexagon head bolts to 25 Nm and then turn 90° further. 1.2.2 Carrying out check measurement –…

  • Page 167: Output Shaft

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Output shaft Dismantling and assembling output shaft Special tools and workshop equipment required ♦ Press tool -VW 407- ♦ Press tool -VW 412- ♦…

  • Page 168
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Pressure plate -VW 402- ♦ Thrust piece -32 — 111- ♦ Press tool -VW 408 A- ♦ Press tool -VW 409- ♦…
  • Page 169
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Drift sleeve -30 — 100- ♦ Tube -VW 415 A- ♦ Thrust pad -VW 447 H- ♦ Thrust piece -VW 454- ♦…
  • Page 170
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Internal puller -1- Kukko 21/6- ♦ Counter support -4- Kukko 22/2- ♦ Splitter -3- Kukko 17/2- Note The output shaft is dismantled as follows: position separating device under 2nd gear synchromeshed gear ♦…
  • Page 171
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 1 — Hexagon nut, 25 Nm and then turn 90° further ❑ 4 nuts for bearing sup‐ port ❑ Always renew…
  • Page 172
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ❑ Check for wear ⇒ page 172 16 — Locking collar with synchro-hub for 1st and 2nd gears ❑ After removing retaining ring ⇒…
  • Page 173
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 31 — Synchro-ring for 4th gear ❑ Check for wear ⇒ page 175 32 — Synchromeshed gear for 4th gear…
  • Page 174
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Pressing in small tapered roller bearing outer race Pulling off small tapered roller bearing inner race A — Vice with protective jaws –…
  • Page 175
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Pressing off locking collar with synchro-hub and bearing support – First remove retaining ring -arrow-. Pulling off large tapered roller bearing inner race A — Protective jaws –…
  • Page 176
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Checking 1st and 2nd gear inner ring for wear – Press inner ring onto cone of synchromeshed gear and meas‐…
  • Page 177
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Assembly of 1st and 2nd gear locking collar and synchro-hub with hollow locking pieces • Locking collar has been pushed over synchro-hub.
  • Page 178
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Installation position of 2nd gear outer ring Lugs -arrows- face 1st gear -A-. Installation position of synchro-ring (2nd gear inner ring) -A- Lugs -arrow 1- engage in notches -arrow 2- in synchro-ring -B-.
  • Page 179
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Checking synchro-rings for 3rd and 4th gear for wear – Press synchro-ring onto cone of synchromeshed gear and measure gap -a- using feeler gauge.

  • Page 180: Adjusting Output Shaft

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Installation position of locking collar with synchro-hub for 3rd and 4th gears Chamfer -arrow- faces 4th gear. Pressing on synchro-hub with locking collar for 3rd and 4th gears…

  • Page 181
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Special tools and workshop equipment required ♦ Universal dial gauge brack‐ et -VW 387- ♦ End dimension plate — VW 385/17- ♦…
  • Page 182
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Adapter -VW 771/15- It is necessary to readjust the output shaft when the following components are renewed: ♦ Output shaft ♦…
  • Page 183
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Set up dial gauge (3 mm measuring range) and set to “0”with 1 mm preload. -A- = threaded spindle from puller —Kukko 18/0- .
  • Page 184
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Bearing play = Shim (0.65 mm shim thickness (mm) plus determined measured val‐ 1.290 … 1.339 1.450 1.340 … 1.389 1.500…

  • Page 185: Reverse Shaft

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Reverse shaft Dismantling and assembling reverse shaft Special tools and workshop equipment required ♦ Thrust piece -VW 454- ♦ Thrust pad -VW 447 H- ♦…

  • Page 186
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Note After dismantling, always renew needle bearing in clutch housing and reverse shaft support. 1 — Clutch housing 2 — Needle bearing ❑…
  • Page 187
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Pressing needle bearing -A- into clutch housing Pressing needle bearing out of reverse shaft support Pressing needle bearing into reverse shaft support…

  • Page 188: Final Drive — Differential

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 39 – Final drive — differential Renewing flange shaft oil seals with gearbox installed Renewing oil seal for left flange shaft…

  • Page 189: Distinguishing Seals For Right Flange Shaft

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 – Raise drive shaft as high as possible and secure. Take care not to damage paint on drive shaft in the process.

  • Page 190: Renewing Seal (Two-Part Seal And Sleeve For Right Flange Shaft)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 There are different versions. Seal -1- and sleeve -2- are two parts. Identification: notches along circumference of sleeve -arrow-. Renew seal ⇒…

  • Page 191
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Torque wrench -V.A.G 1331- 1.3.1 Removing – Remove noise insulation ⇒ General body repairs, exterior; Rep. Gr. 50 ; Noise insulation .
  • Page 192
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 1.3.2 Installing – Drive in new seal to stop, being careful not to cant seal. – Half-fill space between sealing lip and dust lip with sealing grease -G 052 128 A1- .

  • Page 193: Renewing Seal And Sleeve Together (One-Piece Seal And Sleeve For Right Flange Shaft)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 1.3.3 Torque setting Flange shaft to gearbox (countersunk bolt) ⇒ Item 12 (page 195) Renewing seal and sleeve together (one-piece seal and sleeve for right…

  • Page 194
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Drip tray for workshop hoist -VAS 6208- 1.4.1 Removing – Remove noise insulation ⇒ General body repairs, exterior; Rep. Gr. 50 ; Noise insulation .
  • Page 195
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 1.4.2 Installing – Clean seat for seal in gearbox. – Pull in seal and sleeve together. A — Screw spindle of assembly tool -3066- into threaded piece of differential.

  • Page 196: Adjustment Overview

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Adjustment overview Note If repairs have been carried out to the gearbox, it is necessary to adjust the input shaft, output shaft or differential only if compo‐…

  • Page 197: Differential

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Differential Dismantling and assembling differential Special tools and workshop equipment required ♦ Tapered roller bearing pull‐ er -V.A.G 1582- ♦ Adapter -V.A.G 1582/3- ♦…

  • Page 198
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 ♦ Press tool -VW 408 A- ♦ Thrust piece -VW 473- ♦ Thrust plate -30 — 205- ♦ Sleeve -3144- ♦…
  • Page 199
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Note Heat tapered roller bearing inner race to 100° C before installing. ♦ Always renew both tapered roller bearings together as a set.
  • Page 200
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 12 — Countersunk bolt, 25 Nm ❑ Screw into threaded piece ⇒ Item 20 (page 196) 13 — Flange shaft ❑…
  • Page 201
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Pressing tapered roller bearing outer race into clutch housing No shim is installed in the clutch housing end. Pulling off tapered roller bearing inner races –…
  • Page 202
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Pressing tapered roller bearing outer race into gearbox housing – Fit shim under outer race. – Support gearbox housing directly below bearing mounting us‐…
  • Page 203
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Removing spring pin without circumferential groove (long spring pin); pressing out differential pinion pin When pressed out, spring pin will be sheared off.

  • Page 204: Adjusting Differential

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Installation position of thrust washer for tapered ring -1-. The shoulder -arrow- points towards spring -B-. Some gearboxes have lugs -A-.

  • Page 205
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 It is necessary to readjust the differential when the following com‐ ponents are renewed: ♦ Gearbox housing ♦ Clutch housing ♦…
  • Page 206
    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ 6-speed manual gearbox 02S — Edition 07.2009 Bearing play Shim 0.303 … 0.449 0.650 0.450 … 0.499 0.700 0.500 … 0.549 0.750 0.550 … 0.599 0.800 0.600 … 0.649 0.850…

Источник

Volkswagen Golf V / Golf Plus / Jetta / Touran с бензиновыми двигателями: BCA/BKG/BLN 1.4 л FSI/TSI (1390 см³) 75-90-170 л.с./55-66-125 кВт, BGU/BSE/BSF 1.6 л (1595 см³) 102 л.с./75 кВт, BAG/BLF/BLP 1.6 л FSI (1598 см³) 115 л.с./85 кВт, AXW/BLR/BLX/BLY/AXX/BPY 2.0 л FSI/TSI (1984 см³) 150-200 л.с./110-147 кВт и дизельными BRU/AVQ/BJB/BKC/BLS 1.9 л TDI (1896 см³) 90-105 л.с./66-77 кВт, BDK/AZV/BKD/BMM 2.0 л SDI/TDI (1968 см³) 75-136-140-170 л.с./55-100-103-125 кВт; Руководство по эксплуатации, техническому обслуживанию и ремонту, полные технические характеристики, устройство, цветные электросхемы, диагностика, ремонт, особенности конструкции. Производственно-практическое издание Фольксваген Гольф 5 (1K1), Гольф плюс (1KP), Джетта (1K2) и Туран (1T1) модели выпуска с 2003 года



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Видео VW Golf V/ Golf Plus/ Jetta/ Touran замена ремня ГРМ и стекла зеркала заднего вида/ guide for removing the wing mirror glass (Гольф 5/+ и Туран 2003)

Volkswagen Golf Mark V / Golf Plus / Jetta / Touran общая информация (Фольксваген Гольф 5, Гольф плюс, Джетта и Туран)

Данное Руководство предназначено для того, чтобы автолюбитель мог грамотно обсудить и спланировать ремонт автомобиля с профессиональным механиком или выполнить его своими силами. Руководство поможет Вам определить, какую необходимо сделать работу (даже если вы решите, что Вам могут выполнить ее в мастерской), провести диагностику и предоставить информацию о техническом состоянии, определить последовательность действий и диагностики при обслуживании или ремонте. Тем не менее, надеемся, что Вы воспользуетесь данным Руководством именно для самостоятельного выполнения работ.
Проведение простых работ займет намного меньше времени, чем обслуживание автомобиля в мастерской, куда необходимо дважды приехать, чтобы оставить и забрать автомобиль. И, конечно же, самое главное, можно с:экономить немного денег, которые уйдут на оплату работы.
Для проведения технического обслуживания и ремонта необходимо иметь хороший набор метрических гаечных ключей, отверток и измерительных щупов, так как эти простейшие ручные инструменты используются при выполнении большинства работ. Иногда для ремонта необходимы спец инструменты или специальная подготовка. Об этом говорится в предупреждениях, изложенных в данном руководстве.

В Руководство включены рисунки и описания, показывающие функцию различных деталей и их расположение. Работы описываются и фотографируются в поэтапной последовательности, благодаря чему может выполнить даже новичок. Руководство состоит из 11 Разделов. Разделы поделены на Части и Главы. Имеется много иллюстраций, особенно в тех частях, где приводится детальная последовательность операций, которые нужно выполнит. Текст сопровождается пояснительными иллюстрациями. Они пронумерованы десятичными числами в соответствии с номером Главы и номером пункта в ней, например: 6.4 — иллюстрация относится к пункту 4 Главы 6. В начале Руководства дается подробное Содержание, по которому можно легко найти интересующий Вас вопрос.
«Лево» или «право» автомобиля рассматривается относительно человека, который сидит на сидении водителя лицом вперед. Если не оговорено чего-либо другое, гайки и болты отвинчиваются поворачиванием против часовой стрелки и закручиваются поворотом по часовой стрелке. Производители постоянно модифицируют автомобили, внося изменения в спецификации, технические условия и рекомендации и при уведомлении мы как можно быстрее вносим их в наше Руководство.

Пятый модельный ряд автомобилей VW Golf был представлен покупателю в сентябре 2003 года. Этот модельный ряд включает автомобили с кузовом «седан», Golf Plus и Jetta. Со сменой модельного ряда происходит почти вынужденное увеличение размеров кузова. Golf пятого поколения также стал больше в сравнении со своим предшественником. Он стал длиннее предыдущей модели на 55 мм, шире на 24 мм и выше на 41 мм при габаритах 4204 мм в длину и 1759 мм в ширину. VW Golf имеет объемную систему пассивной безопасности, элементам и которой являются подушки безопасности водителя, переднего пассажира, боковые подушки безопасности и подушки в подголовниках, натяжители ремней безопасности на передних сиденьях.
Автомобили серийно оборудуются системой стабилизации устойчивости (ESP) и усилителем тормозной системы. Усилитель тормозной системы предназначен для экстренной остановки автомобиля в случае аварийной ситуации благодаря гидравлическому приводу. Устройство увеличивает тормозное усилие даже при легком нажатии на педаль тормоза и таким образом сокращает тормозной путь в экстренных ситуациях. Автомобили Golf оснащаются разными по мощности, рабочему объему и конструкции бензиновыми и дизельными двигателями. Этим обеспечивается возможность выбора между экономичными или мощными спортивными автомобилями в соответствии с персональными потребностями и запросами. Мощность двигателя реализуется как на привод только передних колес, так и полный привод всех четырех колес.
Golf Plus
Golf Plus появился: в продаже в январе 2005 года. В сравнении с автомобилями с кузовом «Седан» он выше, а задние фонари оборудованы светодиодными лампочками.

Jetta
Автомобили Jetta в продаже с августа 2005 года. Заднее стекло имеет плавный наклон, что придаёт автомобилю контур седана. Задние фонари, как и у Golf Plus комплектуются светодиодными лампочками.
Touran
В марте 2003 года в продажу поступил компактный вэн Touran. В салоне Touran установлены пять сидений, а при необходимости может дополнительно устанавливаться шестое. Преимуществом Touran является возможность изменения конфигурации салона и его большая вместимость, составляющая 1989 литров.
Коллектив создателей данного Руководства благодарит Вас за покупку книги и желает успехов в обслуживании и ремонте Вашего автомобиля. Убеждены, что книга окажется Вам полезной.

Габаритные размеры Фольксваген Гольф 5, Гольф плюс и Туран (dimensions VW Golf V/ Golf Plus/ Touran)Габаритные размеры Фольксваген Гольф 5 ГТИ (dimensions VW Golf V GTI)

Основные технические характеристики (General technical specifications) VW Golf 5 GTI 2007 трехдверный с мотором 2.0 литра

№ Спецификация / Specs Данные
Габариты (мм/mm) и масса (кг/kg) / Dimensions and Weight
1 Длина / Length 4204 (4213-4216 GTI)
2 Ширина (без/с зеркалами) / Width 1759 (1759-1779 GTI)
3 Высота (загружен/пустой) / Height 1485 (1501 GTI)
4 Колёсная база / Wheelbase 2578
5 Дорожный просвет (клиренс) / Ground clearance 115 (89 GTI)
6 Снаряжённая масса / Total (curb) weight 1335
Полная масса / Gross (max.) weight 1860

Двигатель / Engine
7 Тип / Engine Type, Code Бензиновый, жидкостного охлаждения, четырехтактный, AXX
8 Количество цилиндров / Cylinder arrangement: Total number of cylinders, of valves 4-цилиндровый, 16V, рядный, DOHC с верхним расположением двух распределительных валов
9 Диаметр цилиндра / Bore 82.5 мм
10 Ход поршня / Stroke 92.8 мм
11 Объём / Engine displacement 1984 см³
12 Система питания / Fuel supply, Aspiration Непосредственный впрыск топлива, TSI, Motronic MED 9.1
Двухступенчатый турбонаддув и промежуточное охлаждение наддувочного воздуха
13 Степень сжатия / Compression ratio 10.5:1
14 Максимальная мощность / Max. output power kW (HP) at rpm 147 кВт (200 л.с.) при 5100-6000 об/мин
15 Максимальный крутящий момент / Max. torque N·m at rpm 280 Нм при 1800-5000 об/мин

Трансмиссия / Transmission
16 Сцепление / Clutch type Однодисковое, сухое, с диафрагменной нажимной пружиной и гасителем крутильных колебаний, постоянно замкнутого типа
17 КПП / Transmission type МКПП 6 шестиступенчатая механическая, двухвальная, с синхронизаторами на всех передачах переднего хода

О Книге

  • Название: Volkswagen Golf V / Golf Plus / Jetta / Touran Руководство по ремонту и эксплуатации
  • Бензиновые двигатели: BCA/BKG/BLN 1.4 л FSI/TSI (1390 см³) 75-90-170 л.с./55-66-125 кВт, BGU/BSE/BSF 1.6 л (1595 см³) 102 л.с./75 кВт, BAG/BLF/BLP 1.6 л FSI (1598 см³) 115 л.с./85 кВт, AXW/BLR/BLX/BLY/AXX/BPY 2.0 л FSI/TSI (1984 см³) 150-200 л.с./110-147 кВт и дизельными BRU/AVQ/BJB/BKC/BLS 1.9 л TDI (1896 см³) 90-105 л.с./66-77 кВт, BDK/AZV/BKD/BMM 2.0 л SDI/TDI (1968 см³) 75-136-140-170 л.с./55-100-103-125 кВт
  • Выпуск с 2003 года
  • Серия: «Авторемонт»
  • Год издания: 2007
  • Автор: Коллектив авторов
  • Издательство: «Ассоциация независимых издателей»
  • Формат: PDF
  • Страниц в книге: 264
  • Размер: 57.09 МБ
  • Язык: Русский
  • Количество электросхем: 28

Volkswagen Golf V / Golf Plus / Jetta / Touran Руководство по эксплуатации, техобслуживанию и ремонту

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