VOLKSWAGEN GOLF VARIANT 2007 (16) PDF Document

The repair groups covered are:

• 00 – Technical data
• 30 – Clutch
• 34 – Controls, housing
• 35 – Gears, shafts
• 39 – Final drive – front differential

The required gear oil for the dual clutch gearbox 0AM in the VOLKSWAGEN GOLF VARIANT 2007 is 1.7 l of gear oil -G 052 171-.

The required hydraulic oil and power steering oil for the Mechatronic unit for dual clutch gearbox -J743- in the VOLKSWAGEN GOLF VARIANT 2007 is 1 l central hydraulic oil and power steering oil -G 004 000-.

The torque setting for the cover fitted over the engaging levers on the gearbox in some VOLKSWAGEN GOLF VARIANT 2007 vehicles is 8 Nm.

The recommended tool for working with smaller bolts having low tightening forces on the VOLKSWAGEN GOLF VARIANT 2007 gearbox is Torque wrench 2…10 Nm -V.A.G 1783-.

The 3 most important functions are:

• Adapting installation information
• Reading measured values for mandatory reporting
• Initiating basic adjustment

Pressing the Adapt installation information lock button instructs the mechatronic unit to forget all communication partners. All “active partners” are detected once again the next time the ignition system is switched on.

The Adapt installation information function should always be performed after the following activities:

• After a selector lever has been installed.
• After another control unit has been installed, e.g. engine, ABS or gateway.
• After work on the steering wheel paddle.

The basic adjustment should be initiated:

• if you are prompted to do so in “guided fault finding”
• after you have processed a fault entry
• after you have installed another gearbox
• after you have installed a clutch
• or after you have installed a mechatronic unit

The special tools required for removing and installing the dual clutch on the VOLKSWAGEN GOLF VARIANT 2007 are:

• Hook -3438-
• Support device -T10323-
• Assembly tool -T10356-
• Puller -T10373-
• Thrust piece -T10376-

If the retaining ring is seated very tightly, press the clutch down slightly. Never strike the clutch or shaft with a hammer! Set up the tools -T10323-, -T10376-, and -T10356/5- in parallel to the gearbox flange and secure engine support with bolts -A-.

Clutch should only be pressed down slightly. Often, it is sufficient to rotate spindle against thrust piece -T10376- without pressing. This will “release” retaining ring.

The required special tools for adjusting the position of engagement bearings “K 1 and K 2” on the VOLKSWAGEN GOLF VARIANT 2007 are Gauge block -T10374- and Ruler -T40100-.

The procedure to find dimension “B” is:

• Install retaining ring of outer input shaft.
• Place a ruler -T40100- on its side on flange of clutch housing. It should lie sideways on shaft end.
• Place digital depth gauge onto outer input shaft.
• “Zero” depth gauge.
• Measure distance from retaining ring.
• Note down result and call it “B”.

Measure dimension “B” again on opposite side. Remove retaining ring again (This ring is not allowed to be installed again!). Calculate average of both measuring results to get final dimension “B”.

The depth of bearing in each gearbox should be 50.08 millimetres for clutch 1 on the VOLKSWAGEN GOLF VARIANT 2007.

A clutch tolerance value between minus 0.40 and plus 0.40 millimetres is provided with a new clutch for the VOLKSWAGEN GOLF VARIANT 2007.

The depth of bearing in each gearbox should be 34.35 millimetres for clutch 2 on the VOLKSWAGEN GOLF VARIANT 2007.

The procedure to find dimension “A1” is:

• Install retaining ring of outer input shaft.
• Place a ruler -T40100- on its side on flange of clutch housing.
• Place digital depth gauge “at top” onto outer input shaft.
• “Zero” depth gauge.
• Measure distance from “shaft end” into gauge block -T10374- (placed on “large” engagement bearing).
• Calculate average of both measurements onto gauge block -T10374- and note down as “A1”.

The height of gauge block -T10374- for clutch “K 1” on the VOLKSWAGEN GOLF VARIANT 2007 is 51.81 mm.

The procedure to find dimension “A2” is:

• Place gauge block -T10374- on small bearing “with large opening upwards”.
• Place digital depth gauge “at top” onto outer input shaft.
• “Zero” depth gauge.
• Measure distance from “shaft end” into gauge block -T10374- .
• Calculate average of both measurements onto gauge block -T10374- and note down as “A2”.

The height of gauge block -T10374- for clutch “K 2” on the VOLKSWAGEN GOLF VARIANT 2007 is 36.20 mm.

The calculated shim thickness to shim to be installed (in millimetres) table for the VOLKSWAGEN GOLF VARIANT 2007 clutch adjustment is:

From the supplied shims, select the one that is required. WARNING: Later on, only insert this 1 shim. Not 2 shims.

The torque setting for screwing on the engaging lever with 2 new bolts during VOLKSWAGEN GOLF VARIANT 2007 clutch installation is 8 Nm + 90°.

The torque setting for the bolts when securing the engine support bracket -10 – 222 A- is 8 Nm.

The installation position of the retaining ring joint is “narrower at top”. If you can insert the retaining ring, the clutch is correctly pressed on to stop. Then insert the new retaining ring.

The procedure for checking the selector lever cable on the VOLKSWAGEN GOLF VARIANT 2007 is:

• Move selector lever to position “P” position.
• Remove cable from lever on gearbox.
• Move selector lever repeatedly from “P” to “S” and back to “P”. The selector lever must move easily.
• Reinstall cable with “loosened” adjustment screw. If you remove the securing clip, you must always install a “new” securing clip.
• Adjust cable.

The selector lever cable must always be adjusted whenever:

• The selector lever cable has been removed from the gearbox.
• The engine and/or gearbox has been removed and installed.
• Parts of the assembly mounting have been removed and installed.
• The cable itself or the selector mechanism has been removed and installed.
• The position of the engine and gearbox is shifted, for example to install it free of tension.

The adjustment procedure for the selector lever cable on the VOLKSWAGEN GOLF VARIANT 2007 is:

• Move selector lever in vehicle to “P” position. The adjuster screw -arrow- must be “loosened”.
• Shift lever on gearbox to position “P”. The gearbox lever must be pressed “completely to right side of vehicle” in the direction of selector lever cable support bracket.
• Install Bowden cable with loosened adjusting screw -arrow and new securing clip.
• Gently push handle of selector lever forwards and backwards but under no circumstances must you shift out of “P”. In this way the inner cable of the Bowden cable finds its optimal position.
• Tighten adjusting screw -arrow- to 13 Nm. This completes the adjustment.

If the mechatronic unit cannot be set to removal position with the vehicle diagnostic tester, move the unit by hand to this position by following these steps:

• First reposition mechatronic unit on gearbox housing and secure it with one bolt.
• Move selector lever to position “P” position.
• Turn assembly lever -T10407- anticlockwise. In this way, engaging levers are pressed away from plungers -direction of arrow-. The assembly lever -T10407- must remain inserted between engaging lever and gearbox housing for the entire process.
• If necessary, press assembly lever -T10407- against gearbox using a screwdriver.

All selector forks must be “in neutral” prior to installation of the mechatronic unit. Make sure that all selector forks are located in -N-, “in the middle”, and therefore that the gearbox is in neutral. Check each of 4 selector forks by hand. Every selector fork has 3 positions: “gear selected – neutral – gear selected”. Also, move each fork into each position in succession. Then disengage all gears and return selector forks to middle position “neutral”. “Neutral, neutral, neutral”, or gearbox will not function!

For M12 bolts on the VOLKSWAGEN GOLF VARIANT 2007 with a 1.4 l/90 kW TFSI engine, 1.4 l/118 kW TSI engine, or 1.6 l/75 kW MPI engine, the torque setting is 80 Nm. If insert 18 mm -T10179- is used, the torque is 65 Nm. For M10 bolts, the torque setting is 40 Nm.

For M12 bolts on the VOLKSWAGEN GOLF VARIANT 2007 with a 1.9 l/77 kW TDI PD engine, the torque setting is 80 Nm. If 18 mm insert -T10179- is used, the torque is 65 Nm. For M10 bolts, the torque setting is 40 Nm.

For M12 bolts on the VOLKSWAGEN GOLF VARIANT 2007 with a 1.6 l/77 kW TDI CR engine, the torque setting is 80 Nm. If 18 mm insert -T10179- is used, the torque is 65 Nm. For M10x50 bolts, the torque setting is 40 Nm. For M12x70 bolts, the torque setting is 80 Nm. For M10x50 bolts at the lower connection, the torque setting is 40 Nm.

The procedure for securing the gearbox on the assembly stand for transporting the gearbox of the VOLKSWAGEN GOLF VARIANT 2007 is to pull off both breather caps -arrows- and close using suitable plugs to achieve an oil-tight seal. Then secure the gearbox on gearbox support -VW 353-.

The torque setting for the new countersunk bolt for the stub shaft when renewing the oil seal for the right stub shaft on the VOLKSWAGEN GOLF VARIANT 2007 gearbox is 30 Nm.

The notes to observe when removing drive shafts to renew the oil seal for the right stub shaft on the VOLKSWAGEN GOLF VARIANT 2007 gearbox are:

• Do not remove both drive shafts from gearbox at the same time. If you do so, it will no longer be possible to hold the opposite front wheel fixed for removing or installing the bolts of the stub shafts.
• Do not remove both stub shafts from gearbox at the same time. If the differential bevel gears turn, it is difficult to reinstall the securing bolts for the stub shafts.

The outer circumference of the new oil seal should be lightly oiled when renewing the oil seal for the right stub shaft on the VOLKSWAGEN GOLF VARIANT 2007 gearbox.

The space between the sealing lip and dust lip of the new seal should be half filled with sealing grease -G 052 128- -arrow- when renewing the oil seal for the right stub shaft on the VOLKSWAGEN GOLF VARIANT 2007 gearbox.

The torque setting for the new countersunk bolt for the stub shaft when renewing the oil seal for the left stub shaft on the VOLKSWAGEN GOLF VARIANT 2007 gearbox is 30 Nm.

The notes to observe when removing drive shafts to renew the oil seal for the left stub shaft on the VOLKSWAGEN GOLF VARIANT 2007 gearbox are:

• Do not remove both drive shafts from gearbox at the same time. If you do so, it will no longer be possible to hold the opposite front wheel fixed for removing or installing the bolts of the stub shafts.
• Do not remove both stub shafts from gearbox at the same time. If the differential bevel gears turn, it is difficult to reinstall the securing bolts for the stub shafts.

The outer circumference of the new oil seal should be lightly oiled when renewing the oil seal for the left stub shaft on the VOLKSWAGEN GOLF VARIANT 2007 gearbox.

The space between the sealing lip and dust lip of the new seal should be half filled with sealing grease -G 052 128- -arrow- when renewing the oil seal for the left stub shaft on the VOLKSWAGEN GOLF VARIANT 2007 gearbox.

The torque setting for the new countersunk bolt for the flange shaft when renewing the seal for the right flange shaft on the VOLKSWAGEN GOLF VARIANT 2007 gearbox is 30 Nm. When tightening, press flange shaft against gearbox so that bolt engages in thread.

The notes to observe when removing flange shafts to renew the seal for the right flange shaft on the VOLKSWAGEN GOLF VARIANT 2007 gearbox are:

• Do not remove both flange shafts from gearbox at the same time. If the differential bevel gears turn, it is difficult to reinstall the securing bolts for the flange shafts.
• Remove drive shaft from gearbox and lay to side. Drive shaft is fixed onto suspension strut with tensioning belt -T10038-.
• You do not need to remove the centre bolt of the drive shaft.

The outer circumference of the new oil seal should be lightly oiled when renewing the seal for the right flange shaft on the VOLKSWAGEN GOLF VARIANT 2007 gearbox.

Half-fill space between sealing lip and dust lip of new seal with sealing grease -G 052 128- -arrow- when renewing the seal for the right flange shaft on the VOLKSWAGEN GOLF VARIANT 2007 gearbox.

The torque setting for the new countersunk bolt for the flange shaft when renewing the oil seal for the left flange shaft on the VOLKSWAGEN GOLF VARIANT 2007 gearbox is 30 Nm. When doing this, press flange shaft against gearbox so that bolt engages in thread.

The notes to observe when removing flange shafts to renew the oil seal for the left flange shaft on the VOLKSWAGEN GOLF VARIANT 2007 gearbox are:

• Do not remove both securing bolts in left and right flange shafts at the same time. If the differential bevel gears turn, it is difficult to reinstall the bolts.
• Remove drive shaft from gearbox and carefully lay to side. Drive shaft is fixed onto suspension strut with tensioning belt -T10038-.
• You do not need to remove the centre bolt of the drive shaft.

Lightly oil outer circumference of new oil seal when renewing the oil seal for the left flange shaft on the VOLKSWAGEN GOLF VARIANT 2007 gearbox.

Half-fill space between sealing lip and dust lip of new seal with sealing grease -G 052 128- -arrow- when renewing the oil seal for the left flange shaft on the VOLKSWAGEN GOLF VARIANT 2007 gearbox.

The torque settings for gearbox installation on the VOLKSWAGEN GOLF VARIANT 2007 are listed under section 4.7 Torque settings “Gearbox to engine” and notes on assembly mounting.