VOLKSWAGEN GOLF PLUS 2009 (01) PDF Document

Before working on the selector mechanism in the engine compartment, remove the complete air filter housing if it is located over the selector mechanism. Refer to Rep. Gr. 23 ; Repairing diesel direct injection system or Rep. Gr. 24 ; Repairing injection system.

The special tools required are Release tool -T10178-.

The special tools and workshop equipment required are Hose clamps to 25 mm -3094-, Sealing tool -T10249-, Hook -3438-, and Torque wrench -V.A.G 1331-.

The torque setting for the Clutch pedal to mounting bracket is 25 Nm. It is noted to renew self-locking nuts.

The torque setting for the Crash bar to steering column mounting bracket is 20 Nm. It is noted to renew bolt for crash bar.

Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque as detailed on page 49.

The specified torque for the crash bar to steering column mounting bracket should be referred to on page 49.

If some cars have damping, return it to installation position when installing the over-centre spring for the VOLKSWAGEN GOLF PLUS 2009 LHD.

Install crash bar -1- and tighten the 2 bolts to specified torque as detailed on page 67, if applicable.

Install trim and cover below trim on drive side as detailed in General body repairs, interior; Rep. Gr. 68.

The torque setting for the Mounting bracket to bulkhead is 25 Nm. It is noted to renew self-locking nuts.

The torque setting for the Crash bar to steering column mounting bracket is 20 Nm. It is noted to renew bolt for crash bar.

Refer to the procedure “Removing gearbox” for required special tools as detailed on page 157.

Observe the following table on the subject of “checking and topping up gear oil”:

All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid carefully with a thread tap.

Always renew self-locking bolts and nuts.

Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary. If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.

Ensure that intermediate plate is correctly seated on engine.

Clean input shaft splines and apply thin coat of grease for clutch plate splines -G 000 100- .

The clutch plate must slide easily to and fro on the input shaft.

Attach bracket -T10346- with bolt -1- to left threaded hole in subframe. In the process, position bracket -T10346- at the same angle as the engine. -1- = Flange bolt M6 x 20.

Secure engine support -3300 A- to bracket -T10346- .

Place a cloth between engine support -3300 A- and oil pan.

In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To install gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39- .

Align arms of gearbox support according to holes in adjustment plate .

Screw in support elements -A – and -C- ( pin -3282/29- ) on adjustment plate as shown.

Place gearbox on engine and gearbox jack .

Align adjustment plate and gearbox parallel to one another.

Screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.

After gearbox has been bolted to engine, remove engine and gearbox jack from gearbox.

Remove engine support -3300 A- and bracket -T10346- .

If small cover plate had been installed behind the right-hand flange shaft -A-, install it -arrows-.

Screw in upper engine/gearbox securing bolts and tighten to specified torque as detailed on page 169.

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque as detailed on page 169.

Remove gearbox bracket -A- -arrows-.

If small cover plate -A- for flywheel behind the right flange shaft -arrows- is installed, remove it.

If exhaust system strut -1- was removed, bolt it onto gearbox and tighten bolt -arrow- to specified torque as detailed in Rep. Gr. 26 ; Exhaust system .

Install charge air hose -arrow 1- or -arrow 2- as detailed in Rep. Gr. 21 ; Charge air system with turbocharger .

For gearboxes for vehicles with start-stop system: join connector -arrow- to gearbox neutral position sender -G701- .

Reconnect reversing light connector -arrow 1-.

Install starter, push on connector -arrow 2- and bolt on wire -arrow 3- as detailed in Electrical system; Rep. Gr. 27 ; Starter .

Install earth strap at upper engine/gearbox connecting bolt.

Attach support -B- to gearbox.

Press pipe/hose line -A- into retainer -B- on gearbox.

Install cable support bracket on gearbox and tighten bolts -arrows- to specified torque as detailed in ⇒ Item 6 (page 131) .

Install gearbox selector lever -A- as detailed on ⇒ page 133 .

Tighten hexagon nut -arrow 4- to specified torque as detailed in ⇒ Item 18 (page 132) .

Spread a small amount of grease on pin of gearbox selector lever -A-. Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

Connect gear selector cable to gearbox selector lever -arrow 1-.

Install relay lever together with cable end-piece as detailed on ⇒ page 134 .

Adjust selector mechanism as detailed on ⇒ page 139 .

Install battery tray, battery cover and battery as detailed in Electrical system; Rep. Gr. 27 ; Removing and installing battery .

Install complete air filter housing as detailed in ⇒ Rep. Gr. 23 or ⇒ Rep. Gr. 24 .

Install engine cover.

Reconnect battery and perform work required after connecting battery as detailed in Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .

Install lower part of front left wheel housing liner as detailed in General body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner .

Install noise insulation as detailed in General body repairs, exterior; Rep. Gr. 50 ; Noise insulation .

If heat shield is installed, remove it from subframe -arrows-.

Screw support -T10036- or support -T10036 A- tightly onto subframe using 2 hexagon socket head bolts M6 × 20 -arrows-.

Secure engine support -3300 A- onto support -A-.

Press engine forwards using spindle of engine support -3300 A- . In the process, observe the following points in particular:

The air conditioning compressor -2- must not contact -arrow the refrigerant line -1-.

The alternator must not contact the refrigerant line.

The pressure pipe must not contact the radiator.

To install gearbox “0A4”, set up gearbox support -3282- with adjustment plate -3282/39- .

Align arms of gearbox support according to holes in adjustment plate .

Screw in support elements -A – and -C- on adjustment plate as shown.

Position engine and gearbox jack under vehicle. Arrow -B- on adjustment plate points in direction of vehicle travel.

Align adjustment plate parallel to gearbox and lock safety support on gearbox.

Then screw pin -3282/29- into hole on gearbox for securing bolt of pendulum support.

Remove lower engine/gearbox connecting bolts.

Separate exhaust system if lower bolts -arrows- cannot be removed.

Push connector -1- onto reversing light switch -F4- .

Install starter, push on connector -arrow 2- and bolt on wire -arrow 3- as detailed in Electrical system; Rep. Gr. 27 ; Starter .

Install earth strap at upper engine/gearbox connecting bolt.

Bolts -arrows- are to be tightened to 40 Nm + 90°.

Bolts -arrows- are to be tightened to 60 Nm + 90°.

Bolts -arrows- are to be tightened to 20 Nm + 90°.

Drive shaft to flange shaft as detailed in Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shaft; Removing and installing drive shafts .

The procedure for Removing and installing cover for gearbox housing and 5th gear is detailed on page 225 .

The procedure for Removing and installing gearbox housing and selector mechanism is detailed on page 226 .

The procedure for Removing and installing input shaft, output shaft, differential and selector forks is detailed on page 227 .

The assembly sequence for removing and installing cover for gearbox housing and 5th gear is detailed on page 228 .

The assembly sequence for Dismantling and assembling gearbox completely is detailed on page 234 .

Gear oil specification for manual gearboxes should be consulted in the Electronic parts catalogue “ETKA” .

Use a clean container with a scale and a 3-litre capacity to catch the oil which runs out.

The selector shaft is locked in place as detailed on page 221.

Drain gear oil by removing oil drain plug -arrow 1- and then pivot pin -arrow 2-.

Install pivot pin -arrow 2- with a new O-ring as detailed in ⇒ Item 7 (page 226) .

Screw in oil drain plug -arrow 1- as detailed in ⇒ Item 17 (page 251) .

Now turn angled rod -A- back to original position -direction of arrow- so that selector shaft can move again.

The oil capacity for a completely dismantled gearbox is 1.9 l.

The oil capacity for a partially dismantled gearbox is 1.7 l.

Check and top up gear oil after installation as detailed on ⇒ page 220 .

Check and top up gear oil before installation as detailed in ⇒ Item 3 (page 250), Oil capacity ⇒ page 2 .

If there is no oil loss, the gearbox oil capacity is X (as indicated in the table).

Determining input shaft shim.

The Thickness of shim according to table should be 1.175 mm.

The Thickness of shim according to table should be 0.95 mm.

Set up measuring appliance and dial gauge.

Rotate input shaft so that tapered roller bearings settle.

Press input shaft in -direction of arrow-.

Bearing play should be min. 0.01 … max. 0.09 mm.

Press outer race of tapered roller bearing without shim into gearbox housing using thrust piece -30 – 205- as detailed on ⇒ page 308 .

Set gearbox housing in place and tighten 5 bolts to 25 Nm.

Attach dial gauge and set to “0” with 1 mm preload.

Move differential up and down. Read and note play indicated on dial gauge. (Example: 0.70 mm.)

The torque setting is ⇒ Item 12 (page 306) .

Install differential.

Always renew sealing rings -arrows- for output shaft bearing support.

The procedure for Dismantling and assembling reverse shaft should be consulted.

The special tools and workshop equipment required are:

Thrust piece -VW 454-

Thrust pad -VW 447 H-

Press tool -VW 411-

Centring mandrel -12 – 551-

Thrust plate -VW 401-

Press tool -VW 408 A-

-1- Internal puller -Kukko 21/2-

-4- Counterhold -Kukko 22/1-

After dismantling, the needle bearing in the clutch housing must always be renewed.

After dismantling, the needle bearing in the reverse shaft support must always be renewed.

Pressing needle bearing -A- into clutch housing.

Pressing needle bearing into reverse shaft support.

Both tapered roller bearing inner races are pressed onto the differential cage in the same way.

Lubricate one-piece thrust washer with gear oil and install.

Install both sun wheels and secure (e.g. with flange shaft).

Insert planet pinions offset 180° and pivot into position.

Press in differential pinion pin (-arrow A-) to first planet pinion.

Place threaded pieces -arrows B- in sun gears.

Installation position: shoulder to sun gear.

Drive differential pinion pin into final position and secure with spring pin.

The shoulder -arrow- points towards spring -B-.

Some gearboxes have lugs -A-.

Lugs -A- face tapered ring -1-.

Press outer race of tapered roller bearing without shim into gearbox housing using thrust piece -30 – 205- as detailed on ⇒ page 308 .

Press in outer race of small tapered roller bearing together with the calculated shim (1.175 mm in example) into gearbox housing using thrust pad -VW 510- .

If the position of the tapered roller bearings is affected when parts are exchanged, the input shaft must be readjusted. See adjustment overview ⇒ page 302 .

Table of shims:

If tapered roller bearings are renewed, adjust differential as detailed on ⇒ page 311 .

Press outer race of tapered roller bearing into clutch housing using thrust plate -30 – 205- as detailed on ⇒ page 307 .

Set gearbox housing in place and tighten 5 bolts to 25 Nm.

Attach dial gauge and set to “0” with 1 mm preload.

Move differential up and down. Read and note play indicated on dial gauge. (Example: 0.70 mm.)

Remove gearbox housing cover -arrow-.

Remove selector fork for 5th gear as follows:

Cover openings with a cloth.

Move selector fork -1- to neutral position.

Remove bolt -2- with selector fork for 5th gear.

Then remove both bolts -arrows- for pivot pins.

Pull out pivot pins.

Remove selector fork.

Spring -3- and locking collar -4- do not need to be removed.

Remove bolts -A- for synchro-hub and gear wheel for 5th gear. To do this, engage 5th gear -arrow 1- and 1st gear -arrows 2- and -3- .

After both gears are engaged, the input shaft and output shaft are locked. The synchro-hub and gear wheel cannot turn. Both bolts can now be loosened.

If shafts are not to be renewed, carefully clean residual locking material out of threaded holes using a thread chaser.

Use puller -T10309- .

First set half sleeve -T10309/1- between 5th gear wheel -A and support for selector fork for 5th gear -B-.

Install 5th gear as detailed on ⇒ page 244 .

Apply sealant -AMV 188 200 03- evenly to sealing surface of gearbox cover.

Install gearbox housing cover as detailed on ⇒ page 225 .

Fit clutch release lever and release bearing as detailed on ⇒ page 103 .

Top up gear oil as detailed on ⇒ page 150 .

Remove 5th gear synchromeshed gear with needle bearing.

The wear limit for the 5th gear synchro-ring is 0.5 mm.

The pointed teeth of the locking collar -arrow 1- and the high shoulder of the synchro-hub -arrow 2- face the gearbox housing.

The synchro-hub supports -arrow 3- align with the cast locking pieces of the 5th gear synchro-ring ( ⇒ page 246 , bottom).

Assemble before installing ⇒ page 269 .

Before installing synchromeshed gear and synchro-ring for 5th gear, press synchro-ring onto cone of synchromeshed gear and measure gap -a- with a feeler gauge.

The installation (new) dimension for the 5th gear synchro-ring gap -a- is 1.1 … 1.7 mm.

Pull off gear wheel for 5th gear.

Drive on gear wheel for 5th gear.

Tighten securing bolts for synchro-hub and gear wheel for 5th gear to specified torque as detailed on ⇒ page 225 .

The outer circumference -arrows- faces 5th gear.

There is a needle bearing beneath the gear wheel for 5th gear. Secure the grips so that the bearing does not come in contact with the gear wheel for 5th gear when the gearbox housing is pulled off.

The circumferential groove -arrow- faces gearbox housing.

Assemble before installing ⇒ page 269 .

Pulling off, from ⇒ page 234 .

Pulling off with synchro-hub for 5th gear, from ⇒ page 234 .

Installation position ⇒ page 246 .

Bolt ⇒ Item 4 (page 225) . Always renew.

Removing and installing ⇒ page 234 .

Socket head bolt, 25 Nm for pivot pin to gearbox housing.

Bolt 1 is 18 Nm for gearbox housing cover.

Bolt 4 is 80 Nm + turn 90° further.

Clean residual locking fluid from threaded holes for synchro-hub securing bolts and 5th gear wheel with a thread chaser. Otherwise the bolts may shear.

Dismantling and assembling ⇒ page 258 .

Adjusting ⇒ page 247 .

Installation position ⇒ page 269 .

Adjusting ⇒ page 247 .

Installation position ⇒ page 269 .

Pull off together with gearbox housing ⇒ page 234 .

Pull off individually ⇒ page 228 .

Dismantling and assembling ⇒ page 269 .

Pull off together with gearbox housing ⇒ page 234 .

Pull off individually ⇒ page 228 .

Always renew.

Always renew.

Always renew.

Qty. 4.

Fits in one position only.

Always renew.

25 Nm.

8 Nm.

For vehicles with start/stop system.

For reverse shaft support. Always renew.

25 Nm and turn 90° further. Always renew.

Repairing ⇒ page 255 .

25 Nm.

5 Nm.

Installing ⇒ page 124 .

Installation position ⇒ page 116 .

Installation position ⇒ page 116 .

Adjusting selector mechanism ⇒ page 139 .

25 Nm.

8 Nm.

Lubricate bearing positions and sliding surfaces. Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

To remove or install securing clip -arrow A-, press spacer bush -arrow B- to stop in direction of arrow -arrow C- using screwdriver and pull off securing clip.

Do not cant spacer bush when pushing down.

Slot in gear lever for securing clip must be visible.

Carefully release tension from spring.

Thrust piece -T10083- is required for Dismantling.

Fit gear lever guide in selector housing.

Pin -arrow 1- is still located in notch in selector housing.

Turn gear lever guide in -direction of arrow 2- until ball stud -A- is located in notch in selector housing.

Place selector housing with gear lever guide into larger recess -arrow- in thrust piece -T10083- .

The gear lever guide must project from the selector housing up to the stop.

Insert end -A- of compression spring into guide from above.

Pull end -B- of compression spring downwards and insert it next to guide (in direction of ball joint).

Please pay attention to guides (⇒ figure above) during the further procedure. They must not be broken off.

Carefully remove selector housing with gear lever guide from thrust piece -T10083- .

Move gate selector lever back to stop (opposite from mounting holes for gear and gate selector cable) -arrow 1-.

Grease ball stud.

Press ball stud into gate selector lever -arrow 2-.

Guides -A- and tabs -B- are not allowed to be damaged.

Lever lower end -arrow 1- of compression spring onto shoulder on gate selector lever as far as stop.

Now pull gear lever guide up to stop and pull ball stud out of gate selector lever -arrow 2-.

Then turn gear lever guide in -direction of arrow 1-.

Pin -arrow 2- must be in notch in selector housing.

Then swing out gear lever guide with gear lever in -direction of arrow 3-.

The lower end of the compression spring (-arrow 1- in figure above) can snap off the shoulder of the gate selector lever out of control during the further procedure. Therefore, carefully press it down off shoulder of gate selector lever.

Slacken ends -A- and -B- by turning both round to right. Ends -A- and -B- must point in opposite directions.

The following points are essential to ensure correct adjustment of selector mechanism:

Moving parts of operating elements and elements transferring force must be in proper condition.

Selector mechanism must move freely.

Gearbox, clutch and clutch mechanism must also be in proper condition.

Gearbox must be in neutral.

Remove air filter housing if bracket -A- and securing mechanism for gear selector cable and gate selector cable are not accessible as detailed in ⇒ Rep. Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing injection system .

Pull locking mechanisms on gate selector cable and gear selector cable end-pieces forward to stop -direction of arrow 1- and then turn to left to lock -direction of arrow 2-.

Press selector shaft down -direction of arrow 1-.

While pressing down selector shaft, turn angled rod -A- in -direction of arrow 2- upwards and at the same time press it in until it engages in selector shaft.

Install gaiter with gear knob and noise insulation. Golf ⇒ page 118 , Golf Plus ⇒ page 120 , Passat ⇒ page 121 .

If noise insulation is present, remove it.

Now secure gear lever as follows:

Select neutral using gear lever.

Guide locking pin -T10027 A- through hole -A- into hole -B-.

Now turn locking mechanisms on gear selector cable and gate selector cable end-pieces clockwise to stop -direction of arrow-.

Spring presses locking mechanism into original position.

Now turn angled rod -A- back to original position -direction of arrow-.

With gearbox in neutral, selector lever must rest in gate for 3rd and 4th gear.

Operate clutch.

Select all gears several times. Pay particular attention to operation of reverse gear lock.

If it continues to be difficult to engage a gear after repeated attempts, repeat adjustment procedure of selector mechanism ⇒ page 139 .

If renewed: adjust output shaft and differential ⇒ page 302 .

18 Nm.

Tighten securing bolts for synchro-hub and gear wheel for 5th gear to specified torque ⇒ page 225 .

Assembling locking collar and synchro-hub ⇒ page 283 , ⇒ page 284 and ⇒ page 284 .

Dismantling ⇒ page 286 .

Assembling locking collar and synchro-hub ⇒ page 286 , ⇒ page 286 and ⇒ page 286 .

Installation position, locking collar and synchro-hub ⇒ page 287 .

Pressing on ⇒ page 287 .

For needle bearing ⇒ page 252 .

Pressing on ⇒ page 287 .

Removing and installing ⇒ page 234 .

Adjustment overview ⇒ page 302 .

Remove selector shaft with selector mechanism cover, placing selector shaft in neutral position. Then remove bolts -arrows and pull selector shaft out of gearbox housing.

For gearboxes with start-stop system: remove gearbox neutral position sender -G701- -arrow-.

Remove both bolts -arrows- for reverse shaft support bracket.

Now remove 3rd bolt -arrow- for reverse shaft support bracket.

Then remove gearbox support -arrow A-.

Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes.

Caution: Do not operate clutch pedal any more.

Remove earth strap at upper engine/gearbox connecting bolt.

Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.

Then raise and secure gear selector cable and gate selector cable.

Remove cable support bracket from gearbox -arrows-.

Remove gearbox selector lever -A- by removing nut -arrow 4-.

Release end-piece from gate selector cable ⇒ page 138 .

Press catch -arrow 2- down to stop and remove relay lever together with cable end-piece. In the process, swing it in direction of operation.

The relay lever was secured with a clip shortly after start of production ⇒ page 135 .

Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

With ignition switched off, disconnect battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .

Remove complete air filter housing if it hinders access to slave cylinder ⇒ Rep. Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing injection system .

Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

Pull gear selector cable off pin.

Remove relay lever together with cable end-piece ⇒ page 134 .

Remove gearbox selector lever -A- by removing nut -arrow 3-.

Remove cable support bracket from gearbox -arrows-.

Then remove gearbox support -arrow A-.

Caution: Do not operate clutch pedal any more.

Remove earth strap at upper engine/gearbox connecting bolt.

Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes.

Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.

Remove securing clip -arrow 2- for gate selector cable from relay lever -B-.

Pull gate selector cable from pin.

Pull securing clip -arrow 3- off relay lever -B- and remove relay lever.

Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

Pull gear selector cable off pin.

Remove complete air filter housing if it is near battery ⇒ Rep. Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing injection system .

With ignition switched off, disconnect battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .

First check whether a coded radio is fitted. If so, obtain anti theft code.

If the lifting eyes of the engine for support bracket -10 – 222 A are covered by a component, for example the air filter, it must be removed now. ⇒ Rep. Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing injection system .

Remove complete air filter housing if it is near battery ⇒ Rep. Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing injection system .

Remove battery and battery tray ⇒ Electrical system; Rep. Gr. 27 ; Removing and installing battery .

Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

Pull gear selector cable off pin.

Release end-piece from gate selector cable ⇒ page 138 .

Press catch -arrow 2- down to stop and remove relay lever together with cable end-piece. In the process, swing it in direction of operation.

Remove gearbox selector lever -A- by removing nut -arrow 3-.

Remove cable support bracket from gearbox -arrows-.

Then raise and secure gear selector cable and gate selector cable.

Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.

Then remove gearbox support -arrow A-.

Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes.

Remove earth strap at upper engine/gearbox connecting bolt.

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

Install slave cylinder and tighten bolts -arrows B- to specified torque ⇒ Item 9 (page 104) .

Then install gearbox support -arrow A- and tighten to specified torque ⇒ page 169 .

Push connector -1- onto reversing light switch -F4- .

Install starter, push on connector -arrow 2- and bolt on wire -arrow 3- ⇒ Electrical system; Rep. Gr. 27 ; Starter .

Install earth strap at upper engine/gearbox connecting bolt.

Attach support -B- to gearbox.

Press pipe/hose line -A- into retainer -B- on gearbox.

Install cable support bracket on gearbox and tighten bolts -arrows- to specified torque ⇒ Item 6 (page 131) .

Install gearbox selector lever -A- ⇒ page 133 .

Tighten hexagon nut -arrow 4- to specified torque ⇒ Item 18 (page 132) .

Spread a small amount of grease on pin of gearbox selector lever -A-. Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

Connect gear selector cable to gearbox selector lever -arrow 1-.

Install relay lever -B- and secure with securing clip -arrow 3-. Spread a small amount of grease on pin of relay lever -B-. Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

Connect gate selector cable to relay lever -arrow 2-.

Adjust selector mechanism ⇒ page 139 .

Install battery tray, battery cover and battery ⇒ Electrical system; Rep. Gr. 27 ; Removing and installing battery .

Install complete air filter housing ⇒ Rep. Gr. 23 or ⇒ Rep. Gr. 24 .

Reconnect battery and perform work required after connecting battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .

Install lower part of front left wheel housing liner ⇒ General body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner .

Install noise insulation ⇒ General body repairs, exterior; Rep. Gr. 50 ; Noise insulation .

For vehicles with front vehicle level sender -G78- , check headlight adjustment ⇒ Electrical system; Rep. Gr. 94 ; Lights, lamps, switches – exterior .

First check whether a coded radio is fitted. If so, obtain anti theft code.

With ignition switched off, disconnect battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .

Then remove engine cover with air filter ⇒ Rep. Gr. 24 ; Repairing injection system .

Remove battery and battery tray ⇒ Electrical system; Rep. Gr. 27 ; Removing and installing battery .

Release end-piece from gate selector cable ⇒ page 134 .

Pull clip -arrow 1- off and remove relay lever together with cable end-piece.

Remove securing clip -arrow 2- for gear selector cable from gearbox selector lever -A-.

Pull gear selector cable off pin.

Remove gearbox selector lever -A- by removing nut -arrow 3-.

Remove cable support bracket from gearbox -arrows-.

Then raise and secure gear selector cable and gate selector cable.

Remove bracket -B- from gearbox and pull it off pipe/hose line -A-.

Then remove gearbox support -arrow A-.

Remove slave cylinder -arrow B-, lay to side and secure with wire. Do not disconnect pipes.

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque as detailed on ⇒ page 186 .

Align engine and gearbox in installation position using both spindles of support bracket -10 – 222 A- .

Install new bolts -arrows- for left assembly mounting in gearbox mounting and tighten to specified torque ⇒ page 186 .

Install engine and gearbox mounting free of tension ⇒ Rep. Gr. 10 ; Removing and installing engine .

Then install drive shafts ⇒ Running gear, axles, steering; Rep. Gr. 40 ; Removing and installing drive shafts .

Install drive shaft heat shield, if present -arrows- ⇒ Running gear, axles, steering; Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .

Install pendulum support ⇒ Running gear, axles, steering; Rep. Gr. 40 ; Repairing front suspension .

Assemble exhaust system and attach exhaust system bracket to subframe ⇒ Rep. Gr. 26 ; Exhaust system .

If front vehicle level sender -G78- -arrows- is present, install it ⇒ Rep. Gr. 40 ; Removing and installing front vehicle level sender -G78- .

Install bracket -A- on gearbox using new hexagonal bolts -arrows- and tighten to specified torque as detailed on ⇒ page 186 .

Then install drive shafts ⇒ Running gear, axles, steering; Rep. Gr. 40 ; Removing and installing drive shafts .

If heat shield was removed, bolt it onto subframe, -arrows-.

Bolts -arrows- are to be tightened to 40 Nm + 90°.

Bolts -arrows- are to be tightened to 60 Nm + 90°.

Bolts -arrows- are to be tightened to 20 Nm + 90°.

When renewing, ⇒ adjustment overview ⇒ page 302 .

For output shaft needle bearing ⇒ page 252 .

Adjustment overview ⇒ page 302 .

Removing ⇒ page 280 .

Pressing in ⇒ page 281 .

Pulling off ⇒ page 281 .

Pressing on ⇒ page 281 .

Adjusting ⇒ page 287 .

Pulling off ⇒ page 282 .

Pressing on ⇒ page 282 .

With large tapered roller bearing outer race and bolts.

Change outer race only together with large tapered roller bearing and bearing support.

Shoulder of thrust washer faces tapered roller bearing.

Removing and installing ⇒ page 303 .

If renewed, adjust differential ⇒ page 311 .

Adjustment overview ⇒ page 302 .

Renewing ⇒ page 296 .

The procedure is detailed on page 294 .

Renew seal and sleeve together ⇒ page 299 .

Renew seal ⇒ page 296 .

⇒ Item 12 (page 306) .

⇒ Item 12 (page 306) .

The oil level in the gearbox can only be checked by completely draining the gear oil and then refilling.

Gear oil specification for manual gearboxes ⇒ Electronic parts catalogue “ETKA” .

Remove complete air filter housing ⇒ Rep. Gr. 23 or ⇒ Rep. Gr. 24 .

Remove noise insulation ⇒ General body repairs, exterior; Rep. Gr. 50 ; Noise insulation .

To drain gear oil, a pivot pin for the selector forks in the gearbox must be removed.

To prevent the positions of the selector forks from being changed, e.g. due to accidental operation of the selector mechanism, the selector shaft must be locked in position.

Press selector shaft down -direction of arrow 1-.

While pressing down selector shaft, turn angled rod -A- in -direction of arrow 2- upwards and at the same time press it in until it engages in selector shaft.

Now turn angled rod -A- back to original position -direction of arrow- so that selector shaft can move again.

Top up oil in container to 1.7 litres.

Remove reversing light switch -F4- -arrow-.

Connect hose (approx. 600 mm long, external diameter 10 mm) to commercially available funnel.

Insert hose in fitting hole for reversing light switch (2nd mechanic) and fill gear oil.

Install reversing light switch -F4- -arrow- ⇒ Item 2 (page 256) .

Check operation of selector mechanism ⇒ page 142 .

Install complete air filter housing ⇒ Rep. Gr. 23 or ⇒ Rep. Gr. 24 .

Install noise insulation ⇒ General body repairs, exterior; Rep. Gr. 50 ; Noise insulation .

Adjusting output shaft (Determining shim for output shaft).

Prerequisites:

Sealing surfaces of clutch and gearbox housings must be free of sealant.

Press outer ring of small tapered roller bearing to stop with 0.65 mm shim into clutch housing ⇒ page 281 .

Insert output shaft and tighten nuts for bearing support to 25 Nm, then turn 90° further.

Turn output shaft 20 to 30 times in one direction.

Set up dial gauge (3 mm measuring range) and set to “0”with 1 mm preload.

Move output shaft up and down. Read and note play indicated on dial gauge. (Example: 1.21 mm).

The Thickness of shim according to table should be 0.900 mm.

The Shim thickness (mm) is 0.750.

If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure.

Press in outer race of small tapered roller bearing together with the shim (1.175 mm in example) into gearbox housing using thrust pad -VW 510- .

Adjusting differential.

Prerequisites:

Sealing surfaces of clutch and gearbox housings must be free of sealant.

Press outer race of tapered roller bearing without shim into gearbox housing using thrust piece -30 – 205- ⇒ page 308 .

Adjustment overview ⇒ page 302 .

If the differential cage is renewed, the differential needs adjustment.

Press outer race of tapered roller bearing into clutch housing using thrust plate -30 – 205- ⇒ page 307 .

Fit differential into clutch housing.

Set gearbox housing in place and tighten 5 bolts to 25 Nm.

Attach dial gauge and set to “0” with 1 mm preload.

Move differential up and down. Read and note play indicated on dial gauge. (Example: 0.70 mm.)

The Thickness of shim according to table should be 0.95 mm.

The Shim thickness (mm) is 0.750.

Lubricate one-piece thrust washer with gear oil and install.

Install both sun wheels and secure (e.g. with flange shaft).

Insert planet pinions offset 180° and pivot into position.

Press in differential pinion pin (-arrow A-) to first planet pinion.

Place threaded pieces -arrows B- in sun gears.

Installation position: shoulder to sun gear.

Drive differential pinion pin into final position and secure with spring pin.

The shoulder -arrow- points towards spring -B-. Some gearboxes have lugs -A-. Lugs -A- face tapered ring -1-.

Cover tapered roller bearing inner race and speedometer drive gear to avoid possible damage and ingress of metal particles.

Drive out spring pin with chisel, inserting chisel into circumferential groove.

Drive into differential cage to stop.

When pressed out, spring pin will be sheared off.

Drive remainder of spring pin out of differential cage.

Align hole in differential pinion pin with hole in differential cage.

Drive in new spring pin with drift -1- until dimension -a- = 3.0 mm is attained.

The spring pin must not come in contact with gears with differential cage installed.

Lubricate one-piece thrust washer with gear oil and install.

Install one-piece thrust washer so that it engages in groove -B- in differential cage.

The wear limit for the 1st and 2nd gear inner ring is 0.3 mm.

The installation (new) dimension for the 1st and 2nd gears gap -a- is 0.75 … 1.25 mm.

The wear limit for the 1st and 2nd gear synchro-ring is 0.5 mm.

The installation (new) dimension for the 1st and 2nd gears gap -a- is 1.2 … 1.8 mm.

Insert locking pieces and install springs offset 120°. Angled end of spring must locate in hollow locking piece.

Insert locking pieces and install springs offset 120°. Springs must seat with angled ends in front of locking pieces -arrows-.

Teeth of locking collar -arrow- face splines for 3rd and 4th gear synchro-hub -A-.

Turn synchro-ring so that grooves align with locking pieces.

1st and 2nd gear selector segments = 11.4 mm.

3rd and 4th gear selector segments = 7.7 mm.

5th gear selector segments = 12.1 mm.

Clamp selector fork in vice with protective jaw covers -B-.

Lever off lock washer -A- in direction of arrow.

Press lock washer into groove of selector segment using socket and spinner handle.

After lock washer is installed, selector segment must still rotate freely.

Removing and installing selector mechanism ⇒ page 136 .

If it continues to be difficult to engage a gear after repeated attempts, repeat adjustment procedure of selector mechanism ⇒ page 139 .

Remove selector mechanism ⇒ page 136 .

Adjusting selector mechanism ⇒ page 139 .

Do not kink selector cables.

I – Removing and installing gear knob and cover ⇒ page 118

II – Repairing gear lever and selector housing (through 10.06) ⇒ page 123

II – Repairing gear lever and selector housing (from 11.06) ⇒ page 125

III – Assembly overview – removing and installing selector cables ⇒ page 131

Removing and installing selector mechanism ⇒ page 136

Adjusting selector mechanism ⇒ page 139 .

Before working on selector mechanism in engine compartment, disconnect earth strap from battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .

When reconnecting battery, perform work required after connecting battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .

Note radio code for vehicles with coded radio.

Installation position ⇒ page 134 for Gearbox selector lever and page 134 for Relay lever.

Wind cable tie -arrow- around the selector cables in a figure eight and secure them as shown in figure.

Lubricate bearing positions and sliding surfaces. Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

Hexagon nut M8, 25 Nm.

Hexagon nut M 6, 8 Nm.

The required tools are:

Base plate.

Seal.

Gear lever.

Damping washer.

Securing clip.

Bush.

Gear lever guide.

Damping washer.

Ball socket.

Bush.

Securing clip.

Compression spring.

Seal.

Base plate.

Gear lever.

Selector housing.

Bearing bush.

Securing clip.

Bearing bush.

Hexagon nut M8, 25 Nm, hexagon nut M 6, 8 Nm.

Bearing bush.

Securing clip.

Remove selector mechanism ⇒ page 136 .

Adjust selector mechanism ⇒ page 139 .

Installing ⇒ page 124

Removing and installing, Golf Plus ⇒ page 120 .

Removing and installing, Golf Plus ⇒ page 120 .