VOLKSWAGEN GOLF PLUS 2005 (06) PDF Document

To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential. Basic rules for safety also apply during repair work.

A number of instructions generally applicable to the various repair procedures are summarised under the topic “components” (refer to page 12). They apply to this workshop manual.

When installing the manual gearbox, ensure that the dowel sleeves between the engine and gearbox are correctly seated.

When installing mounting brackets or waxed components, clean the contact surfaces. Contact surfaces must be free of wax and grease.

Allocate bolts and other components using the Electronic parts catalogue “ETKA”.

If the gearbox is repaired, fill with gear oil.

The capacity of the gearbox when completely dismantled is 1.9 l. The capacity when partially dismantled is 1.7 l (refer to page 220).

Before installing the oil seal, half-fill the space between the sealing lips with sealing grease -G 052 128 A1- (refer to arrow in the figure).

The open side of the oil seal faces the side with fluid filling.

After installing, check the oil level (refer to page 220).

Lightly oil O-rings before installing; this prevents the rings being crushed when inserted.

Thoroughly clean parting surfaces and apply sealant -AMV 188 200 03-.

Apply sealant uniformly but not too thick.

Thoroughly clean housing joint surfaces before applying sealing paste.

Evenly apply a thin coat of sealing paste -AMV 188 200 03-.

Breather holes must remain free of sealing paste.

Renew retaining rings.

Do not overstretch retaining rings.

Retaining rings must locate properly in grooves.

Renew spring pins. Installation position: slot must be in line with direction of force.

Loosen and tighten securing bolts and nuts for covers and housings diagonally.

Do not cant especially delicate parts, such as clutch pressure plates. Loosen and tighten bolts and nuts in stages in a diagonal sequence.

Torque settings are specified for unoiled bolts and nuts.

Always renew self-locking bolts and nuts.

Ensure with threaded connections that contact surfaces as well as nuts and bolts are rewaxed only after assembly, if necessary.

Use a thread chaser to clear residual locking fluid from all threaded holes into which self-locking bolts are to be screwed. Otherwise there is a danger of bolts shearing when subsequently being removed.

Install new tapered roller bearings as supplied and do not lubricate additionally.

Install needle bearings with lettered side (thicker metal) towards fitting tool.

Tapered roller bearings fitted to one shaft must be renewed as a set. Use same make of bearings.

Heat inner races to about 100 °C with the inductive heater -VAS 6414- before installing.

Do not interchange outer or inner races of bearings of the same size. The bearings are matched in pairs.

Measure shims at several points with a micrometer. The various thicknesses make it possible to achieve the exact shim thickness required.

Check for burrs and damage.

Install only flawless shims.

Do not interchange. When reusing synchro-rings, always fit to the same synchromeshed gear.

Check for wear and renew if necessary.

Check grooves -arrow 1- of synchro-ring -A- and inner ring for flat spots (worn grooves).

If synchro-rings are coated, coating must not be damaged.

If an intermediate ring -B- is installed, check the outer friction surface -arrow 2- and inner friction surface -arrow 3- of this intermediate ring for “scoring”, “signs of abnormal wear” and “blue discolouration (due to overheating)”.

Check cone of synchromeshed gear for “scoring” and “signs of abnormal wear”.

Moisten synchromesh mechanism with gear oil before installing.

Before installing, clean and heat with the inductive heater -VAS 6414- to maximum 100° C.

After assembly, check synchromeshed gears for slight play, or for freedom of movement.

Ensure that the pressure plate does not cant: loosen and tighten bolts diagonally and in several gradual stages.

If the clutch has burnt out, thoroughly clean the clutch housing as well as the friction surface of flywheel with a cloth to reduce the smell of burnt linings.

The special tools and workshop equipment required for repairing the clutch mechanism for the VOLKSWAGEN GOLF PLUS 2005 manual gearbox 0A4 are:

Release tool -T10178-

Torque wrench -V.A.G 1331-

The procedure for removing the over-centre spring for the VOLKSWAGEN GOLF PLUS 2005 manual gearbox 0A4 is as follows:

Push driver seat as far back as possible and put steering wheel in highest position.

Remove trim and cover below trim on drive side (refer to General body repairs, interior; Rep. Gr. 68).

Carefully cut through cable tie -1-.

Remove cable guide -2- from steering column.

Remove footwell vent -3- (refer to Heating, air conditioning; Rep. Gr. 80; Repairing heating).

Now remove crash bar -A- from in front of clutch pedal by removing bolt -B-.

Remove footwell trim by removing nuts (indicated by arrows).

Remove bolt -1- and pull universal joint -2- from steering box.

If fitted, remove damping (indicated by arrow) from lower area of clutch pedal mounting bracket.

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 the direction of the arrow.

Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-.

Swing clutch pedal forward slightly and remove over-centre spring -4- from mounting bracket.

Install in the reverse order of removal, observing the following:

Renew self-locking nuts.

Insert over-centre spring in mounting bracket from above.

Receptacle -arrow- for tip -A- of clutch pedal must be vertical.

Insert tip of clutch pedal in bearing recess of over-centre spring.

Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque (refer to page 59).

Some cars have damping -arrow- on the clutch pedal mounting bracket.

Return it to installation position.

Install crash bar -A-, tightening bolt -B- to specified torque (refer to page 36).

Fit universal joint -2- to steering box and screw in new bolt -1- (refer to Running gear, axles, steering; Rep. Gr. 48; Assembly overview – Steering).

Carry out basic setting for steering angle sender -G85- with vehicle diagnosis, testing and information system -VAS 5051-.

Install trim and cover below trim on drive side (refer to General body repairs, interior; Rep. Gr. 68).

The torque settings are as follows:

The identification codes, assembly allocation, and capacities for the 5-speed manual gearbox 0A4 in the VOLKSWAGEN GOLF PLUS 2005 are detailed in the following tables:

The following data can be found in the Electronic parts catalogue “ETKA”:

♦ Individual gear ratios

♦ Gear oil

♦ Clutch allocation

The assembly overview of the hydraulics (LHD) is as follows:

1 – Brake fluid reservoir

2 – Spring-type clip (Not fitted in all vehicles)

3 – Supply hose (Rubber or Plastic from 12.05, Golf 2009 & Golf Plus 2009 plastic refer to page 95)

4 – Master cylinder (Removing and installing refer to page 88)

5 – Clip (Pull out clip to stop to remove and install pipe/hose line)

6 – Retainer (To remove and install, separate master cylinder from clutch pedal for Golf 2004 refer to page 38, Golf 2009 refer to page 44, Golf Plus refer to page 54, Passat refer to page 59)

7 – Clutch pedal (Removing and installing, Golf 2004 refer to page 38, Golf 2009 refer to page 44, Golf Plus refer to page 54, Passat refer to page 59)

8 – Hexagon nut (refer to Item 15 (page 17))

9 – Seal / O-ring (Pull onto line connection, Insert with brake fluid, Seals/O-rings are adapted to configuration of line connection refer to page 95, Allocation refer to Electronic parts catalogue “ETKA”)

10 – Pipe/hose line (Allocation refer to Electronic parts catalogue “ETKA”, To remove, remove battery and battery tray refer to Electrical system; Rep. Gr. 27; Removing and installing battery)

11 – Retainer (Secured to body)

12 – Seal / O-ring (Pull onto line connection, Insert with brake fluid)

13 – Clip (Pull out clip to stop to remove and install pipe/hose line)

14 – Slave cylinder (Removing and installing refer to page 98)

15 – Hexagon bolt (refer to Item 9 (page 104))

16 – Bleeder valve (Bleeding clutch system refer to page 101)

17 – Dust cap

18 – Gearbox

19 – Retainer

20 – Hexagon bolt, 20 Nm

The procedure for removing the mounting bracket for the clutch pedal on the VOLKSWAGEN GOLF PLUS 2005 is as follows:

Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in direction of arrow.

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 cylinder.

Swing clutch pedal down slightly and remove over-centre spring -4- from mounting bracket.

Remove securing nuts -1- and -2-.

The upper securing nut -1- is accessible between the relay carrier and the steering column trim.

Remove mounting bracket -3-.

Install in the reverse order of removal, observing the following:

Note: Renew self-locking nuts.

Push damping upwards in area of upper securing nut -1- above clutch pedal -A- in direction of arrow.

Remove securing nuts -1- and -2-.

The upper securing nut -1- is accessible between the relay carrier and the steering column trim.

Remove mounting bracket -3-.

Install crash bar -1- and tighten bolt -2- to specified torque (refer to page 72).

Continuation for all:

Mount cable guide -2- on steering column.

Install foot well vent -3- (refer to Rep. Gr. 80).

Vehicles with knee airbag:

Install bracket for knee airbag together with crash bar (refer to Interior equipment; Rep. Gr. 69; Airbag; Removing and installing knee airbag bracket (Golf 2009 ▸)).

Continuation for all:

Install trim and cover below trim on drive side (refer to General body repairs, interior; Rep. Gr. 68).

If disconnected, connect battery (refer to Electrical system; Rep. Gr. 27; Removing and installing battery).

The torque settings are as follows:

The procedure for removing the over-centre spring for the clutch pedal on the VOLKSWAGEN GOLF PLUS 2005 is as follows:

Push driver seat as far back as possible and put steering wheel in highest position.

Remove trim and cover below trim on drive side (refer to General body repairs, interior; Rep. Gr. 68).

Remove cable guide -2- from steering column.

Remove footwell vent -3- (refer to Heating, air conditioning; Rep. Gr. 80; Repairing heating).

Now remove crash bar -A- from in front of clutch pedal by removing bolt -B-.

Remove footwell trim by removing nuts (indicated by arrows).

Remove bolt -1- and pull universal joint -2- from steering box.

If fitted, remove damping (arrow) from lower area of clutch pedal mounting bracket.

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.

Unbolt clutch pedal -1- from mounting bracket -3- by removing nut -2- and pulling out bolt -5-.

Swing clutch pedal forward slightly and remove over-centre spring -4- from mounting bracket.

Install in the reverse order of removal, observing the following:

Note: Renew self-locking nuts.

Insert over-centre spring in mounting bracket from above.

Receptacle -arrow- for tip -A- of clutch pedal must be vertical.

Insert tip of clutch pedal in bearing recess of over-centre spring.

Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque (refer to page 36).

Some cars have damping -arrow- on the clutch pedal mounting bracket.

Return it to installation position.

Install crash bar -A-, tightening bolt -B- to specified torque (refer to page 36).

Fit universal joint -2- to steering box and screw in new bolt -1- (refer to Running gear, axles, steering; Rep. Gr. 48; Assembly overview – Steering).

Carry out basic setting for steering angle sender -G85- with vehicle diagnosis, testing and information system -VAS 5051-.

Install trim and cover below trim on drive side (refer to General body repairs, interior; Rep. Gr. 68).

The torque settings are as follows: