VOLKSWAGEN GOLF VARIANT 2007 (13) PDF Document

To ensure successful repairs on the VOLKSWAGEN GOLF VARIANT 2007, maintain cleanliness and use proper tools. Always renew O-rings, seals, and gaskets. When installing the manual gearbox, ensure dowel sleeves between the engine and gearbox are correctly seated. Check gear oil levels following any installation procedures. When using sealant, apply a thin, uniform coat of -AMV 188 200 03- and ensure breather holes remain unobstructed.

Loosen and tighten securing bolts and nuts for covers and housings diagonally. Always renew self-locking bolts and nuts. Torque settings are specified for unoiled hardware. If bolts were secured with locking fluid, clean the threads with a wire brush before re-inserting with fresh locking fluid -AMV 185 100 A1-. All threaded holes for self-locking bolts must be cleaned with a thread chaser to prevent shearing.

The manual gearbox for the VOLKSWAGEN GOLF VARIANT 2007 has the following technical data:

Identification code: KRG / LHY

Engine: 1.4 l – 90 kW

Final drive ratio: 73 : 18 = 4.056

Gearbox oil capacity: 2.0 l

Drive shaft flange diameter: 100 mm

Use brake filling and bleeding equipment -VAS 5234- or -V.A.G 1869-. Prefilling is not necessary.

Step 1. Remove the air filter housing if it blocks access to the slave cylinder.

Step 2. Connect the bleeding equipment to the bleeder valve using a 670 mm bleeder hose -V.A.G 1238/B3- if necessary.

Step 3. Pressurize the system to 2 bar and open the bleeder valve.

Step 4. Bleed off about 100 cm3 of brake fluid and close the valve.

Step 5. Rapidly operate the clutch pedal from stop to stop 10 to 15 times.

Step 6. Open the bleeder valve again and bleed off an additional 50 cm3 of brake fluid.

Step 7. Close the valve and depress the clutch pedal several times.

When removing the slave cylinder on the VOLKSWAGEN GOLF VARIANT 2007, follow these steps:

Step 1. Disconnect the battery and remove the air filter housing if it is located above the slave cylinder.

Step 2. Place a lint-free cloth under the slave cylinder to catch any spilling brake fluid.

Step 3. Pull the clip for the pipe/hose line out of the slave cylinder and pull the line out of the retainer.

Step 4. Unbolt the slave cylinder from the gearbox and remove it. Do not disconnect the hydraulic pipes.

Step 5. To install, reverse the removal steps, ensuring lines are fully inserted until clips engage, and bleed the clutch system afterward.

Caution: Do not operate the clutch pedal while the slave cylinder is removed.

To remove the selector mechanism from the VOLKSWAGEN GOLF VARIANT 2007, ensure the battery is disconnected and the air filter housing is removed if obstructing access. Remove the gaiter with the gear knob, the centre console, and the selector housing nuts. Before detaching the selector cables, pull the locking mechanism forward to the stop and turn to the left to lock. Detach the clips from the relay lever and the gearbox selector lever to free the cables, then remove the selector housing.

Step 1. Remove the noise insulation from underneath the vehicle.

Step 2. Remove the oil filler plug.

Step 3. Check if the oil level is at the lower edge of the filler hole. If the gearbox is correctly filled, the oil should be at this level.

Step 4. If topping up, fill until oil runs out of the filler hole, then reinstall and tighten the plug to the specified torque.

Adjustment is required if the gearbox housing, clutch housing, differential cage, or tapered roller bearings are replaced.

Step 1. Install the differential in the housing without any shim and fit the clutch housing.

Step 2. Attach a dial gauge and set it to 0 with 1 mm of preload.

Step 3. Move the differential up and down and note the play indicated on the gauge.

Step 4. Calculate the required shim thickness by adding the reading to a constant preload value of 0.35 mm.

Step 5. Remove the clutch housing, install the calculated shim thickness, and reassemble.