VOLKSWAGEN JETTA 2005 (16) PDF Document

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What are the repair groups associated with the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The Repair Groups for the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM are:

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

What are the required capacities for the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM components?

The capacities are as follows:

Dual clutch gearbox 0AM	Mechatronic unit for dual clutch gearbox -J743-
1.7 l gear oil -G 052 171-	1 l central hydraulic oil and power steering oil -G 004 000-

Further information in the part number designates the container size.

What torque setting should be used for the cover fitted over the engaging levers on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The torque setting for the cover fitted over the engaging levers on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM is 8 Nm.

How many oil circuits does the 0AM gearbox in the VOLKSWAGEN JETTA 2005 have, and what are they for?

The 0AM gearbox has two oil circuits. One oil fill is for gears, shafts and differential. A 2nd oil fill is for mechatronic unit for dual clutch gearbox -J743-.

What are the three most important functions available when working with vehicle diagnostic testers on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The 3 most important functions are:

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

What must be done to the mechatronic unit when the “Adapt installation information” function is performed on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Pressing the Adapt installation information lock button instructs the mechatronic unit to forget all communication partners.

After which activities should the “Adapt installation information” function always be performed on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

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.

When should the “Initiating basic adjustment” function be performed on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM mechatronic unit?

The basic adjustment should be performed only:

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

What is the special tool required for removing the dual clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The special tool required for removing the dual clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM is Hook -3438-.

What is the procedure to pull off the dual clutch after installing it on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The procedure involves these steps:

Turn gearbox with clutch upwards.
Remove retaining ring of hub -arrow-.
Remove hub with hook -3438- and a screwdriver.
Remove retaining ring of clutch -arrow-.
Pull off clutch.
Remove clutch together with puller -T10373- .

What should be done if the retaining ring for the clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM is seated very tightly?

If the retaining ring is seated very tightly, the cause may be that the clutch is pressing so hard against the retaining ring that the ring is stuck. If you cannot get the ring out of the groove, press the clutch down slightly. Never strike the clutch or shaft with a hammer! Set up the tools that are shown in the illustration. 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.

What components must be removed before adjusting the engagement bearings “K 1 and K 2” on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The components to be removed are:

Remove small engagement bearing.
Remove large engaging lever.
Remove bolts and remove small engaging lever.
Remove retainer for engaging lever.

What tool is required for adjusting the position of engagement bearings “K 1 and K 2” on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The required special tools and workshop equipment are Gauge block -T10374- and Ruler -T40100-.

What is the procedure to find dimension “B” when setting engagement bearings for the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The procedure to find dimension “B” is as follows:

Install retaining ring of outer input shaft -arrow-.
Place a ruler -T40100- on its side on flange of clutch housing. It should lie sideways on shaft end. (Ruler -T40100- should remain in this position during subsequent measurements. Do not turn over, do not remove.)
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. (Do not measure on ring joint. This could force ring away at that point and falsify measuring result.)
Remove retaining ring again. (This ring is not allowed to be installed again!)
Calculate average of both measuring results.

How is the shim for clutch “K 1” calculated for the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The calculation steps for the shim for clutch “K 1” are:

Do not insert any shim!
Place gauge block -T10374- on “large” engagement bearing. Press once onto gauge block -T10374- whilst turning.
Place digital depth gauge “at top” onto outer input shaft. (Ruler -T40100- is already “on its side” on gearbox flange.)
Measure distance from “shaft end” to gauge block -T10374-.
Calculate average of both measurements onto gauge block -T10374- and call it “A1”.
Calculate Depth of engagement bearing of clutch 1: “A1” minus “B” plus height of gauge block -T10374- (which is 51.81 mm).
Calculate actual gap of clutch 1: Calculated value minus nominal dimension “50.08 millimetres”.
Introduce clutch tolerance: Read off value of clutch tolerance of “new” clutch (a value between minus 0.40 and plus 0.40 millimetres is provided).
Final calculation: “your calculated” gap minus or plus the clutch tolerance value.
Refer to table to find correct shim and install.

What warning should be observed when selecting the shim for clutch “K 1” on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

WARNING: Later on, only insert this 1 shim. Not 2 shims.

How is the shim for clutch “K 2” calculated for the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The calculation steps for the shim for clutch “K 2” are:

Only insert small bearing. Do not insert any shim!
By “turning”, check whether small engagement bearing is installed correctly and that grooves are seated correctly.
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 call it “A2”.
Calculate Depth of engagement bearing of clutch 2: “A2” minus “B” plus height of gauge block -T10374- (which is 36.20 mm).
Calculate actual gap of clutch 2: Calculated value minus nominal dimension “34.35 millimetres”.
Introduce clutch tolerance: Read off value of clutch tolerance of “new” clutch.
Final calculation: “your calculated” gap minus or plus the clutch tolerance value.
Refer to table to find correct shim.

What warning should be observed when installing the shim for clutch “K 2” on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

WARNING: Later on, only insert this 1 shim. Not 2 shims. This shim should be under small engagement bearing.

What should be done after installing the dual clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM before continuing with assembly?

Before continuing with assembly, check whether clutch needs to be adjusted. Do not continue with the assembly before the clutch has been adjusted! Adjust positions of engagement bearings.

What caution should be observed when installing the dual clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Caution: Do not oil or grease anything!

What should be done immediately after installing the gearbox on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

After the gearbox has been installed, you must initiate a basic adjustment using the Vehicle diagnosis, testing and information system VAS 5051.

What torque setting is specified for the engaging lever bolts on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The torque setting for screwing on the engaging lever with 2 new bolts is 8 Nm + 90°.

What torque setting is specified for the bolt in the stub shaft when renewing the oil seal for the right stub shaft on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The torque setting for the new countersunk bolt for the stub shaft is 30 Nm.

What should be done to prevent the shim from slipping out of its seat when inserting the clutch during the engagement bearing adjustment on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Secure the shim using 3 drops of glue -AMV 195 KD1 01-. This prevents the shim from slipping out of its seat when the clutch is inserted.

What should be done before installing the cover and lever after renewing the oil seal in the cover on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Always renew the bolt of the lever, and then fit the cover and lever again, attaching the lever again in the same position.

What must be done to the selector lever cable after installing it on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

After installing the selector lever cable, you must adjust it.

What warning should be observed when checking the selector lever cable on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Do not grease connections of cable!

What must be done regarding the securing clip for the selector lever cable when installing it on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

If you remove the securing clip, you must always install a “new” securing clip, because a removed securing clip is not allowed to be installed again as it will have lost its internal tension and so it might fall off.

What must be done to the gearbox lever during selector lever cable adjustment on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The gearbox lever must be pressed “completely to right side of vehicle” in the direction of selector lever cable support bracket.

What is the final step for adjusting the selector lever cable on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Tighten adjusting screw -arrow- to 13 Nm. This completes the adjustment.

What is the emergency release procedure for the selector lever on vehicles from 03.2009 onwards for the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The procedure is to Press onto yellow plastic part -arrow-.

What is the prerequisite before removing the selector lever handle on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Before removal, pull lock button out past its pressure point and secure the locking button with a cable tie or wire against being pressed in. This will prevent the lock button from being accidentally pressed into the handle.

What should be checked on both engaging levers after inserting the 2nd, “larger” engaging lever (for clutch “K 1”) during dual clutch installation on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Check both engaging levers are seated correctly.

What is the warning when checking the selector mechanism on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

WARNING: Before working on vehicle with engine running, move selector lever into position “P” and apply handbrake.

When should the engine not be run if gearbox covers have been unbolted or the gearbox has no fluid on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

If gearbox covers have been unbolted or gearbox has no fluid, do not run engine. Do not tow vehicle.

What safety note is provided regarding the mechatronic unit for dual clutch gearbox -J743- on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

SYSTEM UNDER PRESSURE. DO NOT DISASSEMBLE SYSTEM. System unter Druck. Nicht demontieren. ORGANE SOUS PRESSION. NE PAS DEMONTER.

What is the torque setting for the bolts on the mechatronic unit for dual clutch gearbox -J743- on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The torque setting for Bolt 1 (M8 x 35) is 10 Nm. The torque setting for Bolt 2 (M8 x 90) is 10 Nm.

What should be done when handling the breather on the mechatronic unit for dual clutch gearbox -J743- on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

When doing any work on the mechatronic unit, please remove cap -arrow- from breather and seal with a suitable plug. Protective cover -0AM 325 120- is well suited.

What is the warning about the pressure accumulator when working on the mechatronic unit for dual clutch gearbox -J743- on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

WARNING: Do not work on pressure accumulator. The accumulator is under pressure and is not allowed to be opened.

What caution must be exercised with assembly lever -T10407- when using it to move the mechatronic unit to the removal position on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Assembly lever -T10407- should make contact with gearbox housing with its entire “rear face”. Caution: Housing rib and groove of lever must be flush with one another. Do not insert tool as far as stop.

What is the next step after pressing both engaging levers of the dual clutch “away” from the plungers of the mechatronic unit during its removal from the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The next step is to Turn assembly lever -T10407- anticlockwise. In this way, engaging levers are pressed away from plungers -direction of arrow-. Do not take out assembly lever -T10407- . It must remain inserted between engaging lever and gearbox housing for the entire process.

What must be done to the selector forks before installing the mechatronic unit on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

All selector forks must be “in neutral” prior to installation of 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.

What is the required torque setting when tightening the mechatronic unit diagonally to the gearbox housing on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Tighten mechatronic unit diagonally to 10 Nm.

What should be done to the gearbox oil if the gearbox is installed when renewing the gear oil on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

If the gearbox is installed, you must remove the battery and battery tray to add oil.

What is the caution regarding the amount of oil to fill into the gearbox when renewing gear oil on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Caution: Do not fill any more or any less oil. Malfunctions would result! Gearbox must have precisely 1.7 litres of oil.

What is the required torque setting for the lower bolts when removing the front exhaust pipe to access the gearbox on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM (1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine)?

The torque setting is 8 Nm for the 4 bolts securing the bracket before removing it.

What are the torque settings for the engine/gearbox connecting bolts when removing the gearbox for the 1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine on the VOLKSWAGEN JETTA 2005?

The torque settings are:

Bolt Size	Torque Nm
M12 x 55	80 Nm
M12 x 65	80 Nm
M10 x 50	40 Nm

Arrows point towards dowel sleeves.

What are the torque settings for the engine/gearbox connecting bolts when removing the gearbox for the 1.9 l/77 kW TDI PD engine on the VOLKSWAGEN JETTA 2005?

The torque settings are:

Bolt Size	Torque Nm
M12	80 Nm (If 18 mm insert -T10179- is used: 65 Nm)
M10x50	40 Nm
M12x65	80 Nm
M12x55	80 Nm
M10x50	40 Nm

Arrows point towards dowel sleeves.

What are the torque settings for the engine/gearbox connecting bolts when removing the gearbox for the 1.6 l/77 kW TDI CR engine on the VOLKSWAGEN JETTA 2005?

The torque settings are:

Bolt Size	Torque Nm
M12	80 Nm (If 18 mm insert -T10179- is used: 65 Nm)
M10x50	40 Nm
M12x70	80 Nm
M12x45	80 Nm
M12x155	80 Nm
M12x55	80 Nm
M10x50	40 Nm

Arrows point towards dowel sleeves.

What is the torque setting for the right flange shaft bolt when removing the gearbox with flange shafts on the VOLKSWAGEN JETTA 2005?

The torque setting for the right flange shaft bolt is 30 Nm.

What is the general caution when removing both drive shafts from the gearbox simultaneously when renewing oil seals on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

If you remove both drive shafts from the gearbox at the same time, it will no longer be possible to hold the opposite front wheel fixed for removing or installing the bolts of the stub shafts.

Also, 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.

What is the procedure to install a new oil seal for the right stub shaft on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The procedure is as follows:

Lightly oil outer circumference of new oil seal.
Half fill space between sealing lip and dust lip with sealing grease -G 052 128- -arrow-.
Drive in new seal to stop, being careful not to cant seal. If necessary, it is possible to press a new dust ring onto the stub shaft using tube -2010- . Do not use a hammer.
Insert stub shaft.
Tighten new countersunk bolt for stub shaft to 30 Nm.
Reinstall drive shaft.
Renew gear oil.
Install noise insulation; torque settings.

What is the final step for installing the right flange shaft seal on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Tighten new countersunk bolt to 30 Nm. When doing this, press flange shaft against gearbox so that bolt engages in thread.

What is the torque setting for the left assembly mounting bolts when installing the gearbox on the VOLKSWAGEN JETTA 2005?

The first bolt bracket to gearbox -1- is tightened with 40 Nm + 90° further turn.

What should be done to the selector lever cable routing during installation of the gearbox on the VOLKSWAGEN JETTA 2005?

Ensure that selector lever cable is properly routed during installation -arrow-. If the sheet metal has been bent downwards when the gearbox was removed, it may cause noises. The cable will vibrate against the sheet metal. Observe sheet metal. Press it back up in the tunnel during installation.

What is the general caution regarding oil if the mechatronic unit “jams” and cannot be removed from the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Make sure no oil runs out of breather. Mechatronic unit is to be sent for reconditioning with its oil in.

What is the required torque setting for the bolts when installing the mechatronic unit back onto the gearbox housing on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Screw in 7 new bolts and tighten until finger-tight, then tighten diagonally to 10 Nm.

What should be checked regarding the plungers and engaging levers when installing the mechatronic unit on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Make sure that plungers meet up correctly in cups of engaging levers. Pull out plungers by hand until they are seated in cups. Plungers that are not seated correctly will damage mechatronic unit. Now check seat of plungers again.

What is the procedure to move the mechatronic unit into “removal position” by hand if it cannot be set using the vehicle diagnostic tester on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The procedure is:

First reposition mechatronic unit on gearbox housing and secure it with one bolt.
Move selector lever to position “P” position.

The “sticking” gear actuator -arrow- can be pressed by hand into its “removal position” by pushing a selector fork behind the parking lock cover.

What caution must be observed when securing the gearbox with a tensioning strap -T10038- during gearbox removal on the VOLKSWAGEN JETTA 2005?

When securing both remaining attachments onto the gearbox, place the sheet metal of the drift under the gearbox housing and not under the mechatronic unit.

What is the warning regarding the parking lock when adjusting the selector lever cable on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

WARNING: Be sure that the parking lock is engaged. To do this, turn both front wheels simultaneously “under the car” in the same direction until the parking lock can be heard to engage. The parking lock is engaged when both front wheels cannot be turned in the same direction at the same time.

What should be done to gently push the handle of the selector lever when adjusting the selector lever cable on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM after engaging the parking lock?

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.

What should be done after installing the selector lever cable and before securing it with clips when installing the selector mechanism for vehicles from 03.2009 onwards on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Route selector lever cable without tension. Also insert into cable support bracket on gearbox. Do not secure with securing clips yet. Do not clip in ball head.

What should be done after installing the gear oil if the gearbox is installed when removing the mechatronic unit from the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

After installing the gear oil, perform the basic adjustment.

What is the torque setting for the bolts when attaching the heat shield over the right-hand drive shaft (if fitted) when removing the gearbox for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005?

The tightening torque is specified in Rep. Gr. 40 ; Repairing drive shafts.

What special tools are appropriate for removing the upper connecting bolts between the engine and gearbox when removing the gearbox for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005?

The appropriate tools for this task are T10035, T10061, T10099, and T10179.

What precaution should be taken regarding the selector lever cable when removing the gearbox for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005?

Cable may also be pushed slightly backwards out of cable support bracket and removed later when gearbox is lowered. But then observe cable when lowering gearbox.

What should be done with the pendulum support when removing the gearbox for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005?

Remove pendulum support. Further descriptions can also be found in Running gear, axles, steering; Rep. Gr. 40 .

What is the warning to observe when setting up the support bracket -10-222 A- for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005 during gearbox removal?

If there are hose and cable connections in area of engine support eye for support bracket -10-222 A- , remove these now.

What should be done with the gearbox support -3282- and adjustment plate -3282/59- when removing the gearbox 0AM for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005?

To remove gearbox 0AM, set up gearbox support -3282- with adjustment plate -3282/59- and push onto engine and gearbox support -V.A.G 1383 A- . Align arms of gearbox support according to holes in adjustment plate -3282/59- . Screw in support elements as illustrated on adjustment plate -3282/59- . Position engine and gearbox jack -V.A.G 1383 A- under vehicle. Arrow on adjustment plate -3282/59- points in direction of travel. Align gearbox support -3282- parallel to gearbox. Screw pin -3282/29- into “rear” hole for pendulum support.

What is the torque setting for the left assembly mounting bracket bolts -1- and -2- when preparing to remove the gearbox for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005?

Remove all bolts -1- and -2- for bracket. Then lower engine and gearbox slightly using spindles of support bracket -10 – 222 A- so that bracket can be removed.

What caution should be noted about the distance between the engine flange and gearbox flange when lowering the gearbox for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005?

Distance between engine flange and gearbox flange should be about 50 mm before gearbox is lowered.

What should be done to the needle bearing in the crankshaft when preparing to install the gearbox for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005?

Renew needle bearing in crankshaft -arrow-.

What should be done regarding retainers on the front of the gearbox if a “new” gearbox is being installed for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005?

Remove retainers if installing a “new” gearbox, because there are no retainers on a “new” gearbox.

What should be done regarding the right flange shaft of the gearbox if installing a “new” gearbox for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005?

Install right flange shaft of gearbox with flange shafts.

What should be done to the selector lever cable after installing the gearbox for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005?

Adjust selector lever cable.

What should be done to the breather caps after fitting the starter motor when installing the gearbox for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005?

After fitting starter motor, check that both breather caps are in place -arrows-!

What caution should be observed regarding the securing clip for the selector lever Bowden cable when installing the gearbox for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005?

A securing clip which has been removed is not allowed to be installed again. The clip will have lost its internal tension and so it might fall off. Therefore, when installing, always use a “new” securing clip.

What must be done to ensure the engine and gearbox are aligned after installing the gearbox for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005?

Readjust gearbox support until engine and gearbox are “aligned with each other”. Turn crankshaft slightly if necessary.

What is the torque setting for the bracket bolts -1- and -2- when removing the gearbox for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005?

Remove all bolts -1- and -2- for bracket. Then lower engine and gearbox slightly using spindles of support bracket -10 – 222 A- so that bracket can be removed. At most, 5 turns are sufficient to remove bracket.

What torque setting is specified for the bolt on the left suspension link when removing the gearbox for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005?

The left suspension link is unscrewed from the swivel joint. Unscrew nut -1- from coupling rod -3-.

What special tools are required for removing the gearbox for the 1.9 l/77 kW TDI PD engine on the VOLKSWAGEN JETTA 2005?

The required special tools and workshop equipment are:

Support bracket -10 – 222 A-
Adjustment plate -3282/59-
Adapter -10 – 222 A /8-
Socket -T10061-
Gearbox support -3282-
Insert tool, 18 mm -T10179-
Adapter -10 – 222 A /16-

What is the procedure to prepare the vehicle for removing the gearbox for the 1.9 l/77 kW TDI PD engine on the VOLKSWAGEN JETTA 2005?

The procedure is as follows:

Raise vehicle. All 4 supports of lifting platform must be at same height.
Move selector lever to position “P” position.
Only in vehicles with stub shafts: After loosening centre bolt, do not lower vehicle to ground again. Step on the brake pedal while a 2nd mechanic loosens the two drive shaft bolts -arrow-. Remove both front wheels.
Continuation for all vehicles: Remove complete air filter housing. Remove battery and battery tray. Remove starter. Remove securing clip in -direction of arrow-. Remove Bowden cable from ball head. Cable may also be pushed slightly backwards out of cable support bracket and removed later when gearbox is lowered. But then observe cable when lowering gearbox.
Release mechatronic unit connector by pulling and pull off connector.
Now remove all upper connecting bolts between engine and gearbox.

What must be done to the left suspension link from the swivel joint when removing the gearbox for the 1.9 l/77 kW TDI PD engine on the VOLKSWAGEN JETTA 2005?

Unbolt only left suspension link from swivel joint -arrows-. Swing left drive shaft into wheel housing onto longitudinal member. This will keep the shaft out of the way during further work.

What is the procedure for securing both drive shafts to suspension struts when removing the gearbox for the 1.9 l/77 kW TDI PD engine on the VOLKSWAGEN JETTA 2005?

Secure both drive shafts to suspension struts using tensioning straps -T10038- .

What is the torque setting for the right flange shaft of the gearbox when removing the gearbox for the 1.9 l/77 kW TDI PD engine on the VOLKSWAGEN JETTA 2005?

The torque setting is 30 Nm. The bolt has a 6 mm hexagon socket.

What should be done to the exhaust system bracket from the subframe when removing the gearbox for the 1.9 l/77 kW TDI PD engine on the VOLKSWAGEN JETTA 2005?

Unbolt exhaust system bracket from subframe.

What must be done to the front exhaust pipe so that lower bolts can be removed when removing the gearbox for the 1.9 l/77 kW TDI PD engine on the VOLKSWAGEN JETTA 2005?

Remove front exhaust pipe so that lower bolts can be removed -arrows-.

What must be done to the engine cover from the cylinder head when removing the gearbox for the 1.9 l/77 kW TDI PD engine on the VOLKSWAGEN JETTA 2005?

Remove engine cover from cylinder head.

What should be done with the noise insulation and front part of the wheel housing when removing the gearbox for the 1.9 l/77 kW TDI PD engine on the VOLKSWAGEN JETTA 2005?

Remove noise insulation. Remove front part of wheel housing.

What should be done with retainers and brackets from the front of the gearbox when removing the gearbox for the 1.9 l/77 kW TDI PD engine on the VOLKSWAGEN JETTA 2005?

Remove all retainers and brackets from front of gearbox.

What should be done to the pendulum support when removing the gearbox for the 1.9 l/77 kW TDI PD engine on the VOLKSWAGEN JETTA 2005?

Remove pendulum support.

What should be done with the heat shield over the right-hand drive shaft if fitted, when removing the gearbox for the 1.9 l/77 kW TDI PD engine on the VOLKSWAGEN JETTA 2005?

If fitted, remove the heat shield over the right-hand drive shaft. Tightening torque is specified in Rep. Gr. 40 ; Repairing drive shafts.

What should be done to the drive shafts for vehicles with stub shafts when removing the gearbox for the 1.9 l/77 kW TDI PD engine on the VOLKSWAGEN JETTA 2005?

Remove both drive shafts.

What is the torque setting for the engine/gearbox connecting bolts for the 1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine when installing the gearbox on the VOLKSWAGEN JETTA 2005?

The torque settings are:

Bolt Size	Torque Nm
M12	80 Nm (If insert 18 mm -T10179- is used: 65 Nm)
M10	40 Nm

Arrows point towards dowel sleeves.

What is the torque setting for the bracket when securing it after installing the gearbox for the 1.6 l/75 kW MPI engine on the VOLKSWAGEN JETTA 2005?

The torque setting of -bolts 2- is 60 Nm + 90°.

What is 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 JETTA 2005 7-speed dual clutch gearbox 0AM?

Tighten new countersunk bolt for stub shaft to 30 Nm.

What is the torque setting for the new countersunk bolt when installing the right flange shaft after renewing its seal on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Tighten new countersunk bolt to 30 Nm. When doing this, press flange shaft against gearbox so that bolt engages in thread.

What is the warning regarding dropping the clutch when removing and installing the dual clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The clutch is self-adjusting. Shocks can have an effect on this adjusting device. Therefore, please do not drop the clutch. Do not let the clutch drop into the gearbox either when installing the clutch. Even if the mechatronic unit has been removed, “pulling out” the assembly lever -T10407- under the engaging levers can have a negative effect on the adjusting device.

What should be done to the lever when turning during the removal of the mechatronic unit on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Apply a bit of force to tip of lever when turning. This stops lever from slipping out when turning.

What must be done to the selector lever cable when removing the selector mechanism for vehicles up to 02.2009 on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Disconnect or remove parts of exhaust system. Remove heat shield beneath selector mechanism. Adjust selector lever cable after installing.

What is the bolt torque setting for the gear oil drain plug when renewing gear oil on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The drain plug is installed again with a torque of 30 Nm.

What is the torque setting for the selector lever to selector shaft connection on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The torque setting for the selector lever to selector shaft is specified on page 30.

What is the torque setting for Nut 6 on the selector mechanism for vehicles up to 02.2009 on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The torque setting for Nut 6 is 9 Nm. Quantity: 4.

What is the torque setting for Hexagon flange nut 10 on the selector mechanism for vehicles up to 02.2009 on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The torque setting for Hexagon flange nut 10 is 8 Nm. Quantity: 4.

What warning is given before working on the vehicle with the engine running when servicing the selector mechanism on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

WARNING: Before working on vehicle with engine running, move selector lever into position “P” and apply handbrake.

What bolt torque setting is specified for Bolt 3 on the selector mechanism for vehicles up to 02.2009 on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The torque setting for Bolt 3 with spring is 3 Nm.

What is the note regarding the Bowden cable when installing the selector lever cable for vehicles up to 02.2009 on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Following installation, Bowden cable must be checked for ease of movement and be adjusted.

What is the torque setting for the selector lever to selector shaft when removing and installing the selector lever cable for vehicles up to 02.2009 on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Torque setting, selector lever to selector shaft is specified on page 30.

What is the torque setting for the selector housing bolts when removing and installing the selector mechanism for vehicles from 03.2009 onwards on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The torque setting for the 4 bolts securing the selector housing is 8 Nm.

What should be done to the selector lever to position “P” position before removing the selector mechanism for vehicles from 03.2009 onwards on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Move selector lever to position “P” position.

What is the bolt torque setting for the selector mechanism bolts (3 – Bolt) on the overview of the selector mechanism for vehicles from 03.2009 onwards on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The torque setting for Bolt 3 is 8 Nm.

What is the torque setting for the hexagon flange nut (4 – Hexagon flange nut) on the selector mechanism for vehicles from 03.2009 onwards on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The torque setting for Hexagon flange nut 4 is 8 Nm. Quantity: 4.

What should be done to the selector lever handle before removal for the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Before removal, pull lock button out past its pressure point. Secure locking button with a cable tie or wire against being pressed in. This will prevent lock button from being accidentally pressed into the handle.

What is the warning when checking the selector mechanism on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM with the ignition switched on and the selector lever in “P” position, and the brake pedal not depressed?

Selector lever is locked and cannot be shifted out of “P” position with the lock button pressed. Solenoid for selector lever lock blocks selector lever.

What is the condition for the solenoid for the selector lever lock to release the selector lever when the selector lever is in “P” position and the brake pedal is depressed on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Solenoid for selector lever lock releases selector lever. It is possible to shift into a driving gear. Slowly shift selector lever from “P” through to “S”, checking whether selector lever position in dash panel insert corresponds to selector lever position.

What happens when the selector lever is shifted to position “N” at speeds above 5 km/h on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Solenoid for selector lever lock must not engage and block selector lever. Selector lever can be shifted into a driving range.

What happens when travelling at speeds below 5 km/h (almost stationary) and shifting into selector lever position “N” on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Solenoid for selector lever lock should only engage after about 1 second. Selector lever cannot be shifted out of “N” position until brake pedal is depressed.

What is the procedure to check the selector mechanism when the selector lever is in position “Tiptronic” on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Shift selector lever into Tiptronic gate.

What indicates the gearbox emergency running mode when the ignition and light are switched on for the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Simultaneous illumination of all selector lever position display segments indicates gearbox emergency running mode.

What is the warning when setting up the support bracket -10-222 A- for the 1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine on the VOLKSWAGEN JETTA 2005 during gearbox removal?

If there are hose and cable connections in area of engine support eye for support bracket -10-222 A- , remove these now.

What is the note regarding the gearbox support when supporting the engine and gearbox with support bracket -10-222 A- during gearbox removal for the 1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine on the VOLKSWAGEN JETTA 2005?

Support engine and gearbox with support bracket -10-222 A- but do not raise.

What is the warning regarding the clutch when installing the dual clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

What is the warning when checking the selector mechanism on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM with the ignition switched on and the selector lever in “N” position, and the brake pedal not depressed?

Selector lever is locked and cannot be shifted out of “N” position with the lock button pressed. Solenoid for selector lever lock blocks selector lever.

What should be done to the selector lever cable when removing the selector mechanism for vehicles up to 02.2009 on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

If you are unsure, refer to the illustration for guidance. Remove Bowden cable from ball head. Note installation position of lever and remove it from selector shaft.

What is the warning when checking the selector mechanism on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM with the selector lever in “P” position and the brake pedal depressed?

What is the warning when checking the selector mechanism on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM with the selector lever in “N” position and the brake pedal depressed?

Solenoid for selector lever lock releases selector lever. It is possible to shift into a driving gear.

What are the general repair notes regarding smaller bolts on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Uncertainty often occurs with smaller bolts having low tightening forces. Torque wrench 2…10 Nm -V.A.G 1783- can be used with these bolts.

What is the general note about the gearbox housing on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The gearbox has a hole in the housing. Make sure no small parts drop into this hole during installation work. Cover the hole with a cloth before installation work. Make sure that no dirt can enter an “open” gearbox.

What general precautions should be observed when working on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The following general precautions should be observed:

If gearbox covers have been unbolted or gearbox has no fluid, do not run engine. Do not tow vehicle.
First thoroughly clean connecting points and surrounding areas and then loosen bolts.
During installation, ensure that the dowel sleeves between the engine and gearbox are correctly located.
Place removed parts on a clean surface. Cover parts to prevent soiling. Use plastic sheeting and paper. Use lint-free cloths only!
Install only clean parts; do not remove Genuine parts from packaging until immediately before installing.
If repair work cannot be performed immediately, cover opened parts carefully.

What is the warning regarding oil handling when servicing the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Caution: Use caution when handling oil. Dispose of used oil properly. One drop of oil will contaminate 600 litres of water.

What is the warning regarding the clutch when removing and installing the dual clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Note: The clutch is self-adjusting. Shocks can have an effect on this adjusting device. Therefore, please do not drop the clutch. Do not left the clutch drop into the gearbox either when installing the clutch. Even if the mechatronic unit has been removed, “pulling out” the assembly lever -T10407- under the engaging levers can have a negative effect on the adjusting device.

What is the note regarding the clutch adjustment after installing the gearbox on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

After the gearbox has been installed, you must initiate a basic adjustment using the Vehicle diagnosis, testing and information system VAS 5051.

What caution is given for the gear oil when renewing gear oil on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Caution: Do not fill any more or any less oil. Malfunctions would result!

What is the warning before working on the vehicle with the engine running when checking the selector mechanism on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

WARNING: Before working on vehicle with engine running, move selector lever into position “P” and apply handbrake.

What are the torque settings for the gearbox to engine connections when installing the gearbox for the 1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine on the VOLKSWAGEN JETTA 2005?

The torque settings are:

Bolt Size	Torque Nm
M12	80 Nm (If insert 18 mm -T10179- is used: 65 Nm)
M10	40 Nm

Arrows point towards dowel sleeves.

What is the torque setting for the bracket when securing it after installing the gearbox for the 1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine on the VOLKSWAGEN JETTA 2005?

The torque setting of -bolts 2- is 60 Nm + 90°.

What should be done to the starter when installing the gearbox for the 1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine on the VOLKSWAGEN JETTA 2005?

Install starter.

What should be done to the noise insulation when installing the gearbox for the 1.4 l/90 kW TFSI engine and 1.4 l/118 kW TSI engine on the VOLKSWAGEN JETTA 2005?

Install noise insulation; torque settings.

What is 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 JETTA 2005 7-speed dual clutch gearbox 0AM?

Tighten new countersunk bolt for stub shaft to 30 Nm.

What is the warning about the clutch when installing it on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

What is the warning about the securing clip for the selector lever Bowden cable when installing the gearbox on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

What is the torque setting for the engaging lever bolts during the installation of the dual clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The torque setting for screwing on the engaging lever with 2 new bolts is 8 Nm + 90°.

What must be done to the gearbox lever during the final adjustment of the selector lever cable on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

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.

What must be done to the selector lever cable to check its freedom of movement after installing it on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Move selector lever repeatedly from “P” to “S” and back to “P”. Selector lever must move easily. Reinstall cable with “loosened” adjustment screw.

What torque setting is specified for the upper connecting bolts between the engine and gearbox when installing the mechatronic unit on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Screw in 7 new bolts and tighten until finger-tight, then tighten diagonally to 10 Nm.

What is the note on oil when installing a new mechatronic unit on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

A “new” mechatronic unit is correctly filled with oil. Do not drain oil. A “removed” mechatronic unit is sent back with its oil in. Mechatronic unit remains filled with oil.

What is the torque setting for the bolts when installing the cover after renewing the oil seal in the cover on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The torque settings are 15 Nm and 8 Nm for the cover bolts.

What is the torque setting for the front exhaust pipe lower bolts when removing the gearbox for the 1.6 l/77 kW TDI CR engine on the VOLKSWAGEN JETTA 2005?

The torque settings are M12x45 80 Nm, M12x155 80 Nm, M12x45 80 Nm, M12x55 80 Nm, M10x50 40 Nm, M12x65 80 Nm, M10x50 40 Nm. Arrows point towards dowel sleeves.

What is the torque setting for the left suspension link bolt when removing the gearbox for the 1.6 l/77 kW TDI CR engine on the VOLKSWAGEN JETTA 2005?

The left suspension link bolt is unscrewed from the swivel joint. Then press gearbox off engine, “observing selector lever cable” and lower gearbox. Note: Distance between engine flange and gearbox flange should be about 50 mm before gearbox is lowered.

What is the torque setting for the right flange shaft of the gearbox when removing the gearbox for the 1.6 l/77 kW TDI CR engine on the VOLKSWAGEN JETTA 2005?

The torque setting for the right flange shaft bolt is 30 Nm. The bolt has a 6 mm hexagon socket.

What is the warning about the clutch when pressing it on onto the stop during installation on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Place a hand on clutch whilst pressing on. You will be able to feel a slight rattling. Rattling means the clutch is being pressed onto its press seat. In the same way, you can also “feel” the stop when the clutch has reached its seat.

What is the warning regarding oil contamination when handling oil on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Caution: Use caution when handling oil. Dispose of used oil properly. One drop of oil will contaminate 600 litres of water.

What is the warning regarding the clutch self-adjusting device when working on the clutch adjustment for the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The clutch is self-adjusting. Shocks can have an effect on this adjusting device. Therefore, please do not drop the clutch. Do not left the clutch drop into the gearbox either when installing the clutch. Even if the mechatronic unit has been removed, “pulling out” the assembly lever -T10407- under the engaging levers can have a negative effect on the adjusting device.

What is the torque setting for the engaging lever bolts during installation of the dual clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Screw on engaging lever with 2 new bolts. Torque setting: 8 Nm + 90°.

What is the warning when installing the dual clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Caution: Before continuing with assembly, check whether clutch needs to be adjusted. Do not continue with the assembly before the clutch has been adjusted! Adjust positions of engagement bearings.

What is the caution regarding oil/grease when installing the dual clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Caution: Do not oil or grease anything!

What should be done to the clutch when installing it into the gearbox using puller -T10373- on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Turn spindle “back” first. Press clutch on onto stop. Push clutch down via spindle.

What should be done to the clutch by hand after installing it with puller -T10373- on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

To enable clutch to find its installation position already, turn clutch against puller -T10373- by hand. Now turn clutch by hand, without using a tool. In this way, clutch slides against retaining ring. Do not use any other tool.

What should be done after inserting the hub when installing the dual clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Hub has a “large” tooth and therefore only fits in one position. “Large” tooth has a mark on -engine end- -arrow-.

What is the installation position of the retaining ring for the hub on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Installation position: Joint of ring must point towards “hub” on clutch.

What should be observed when turning the clutch by hand while installing the hub and retaining ring on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Turn clutch by hand and observe “small” engaging lever whilst turning. Engaging levers must remain “still” in their position whilst this is being done. They are not allowed to move up and down. If an engaging lever moves up and down, then shim is not properly seated.

What general precaution should be observed when installing the clutch and hub on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Before clutch is installed, position of engagement bearings “K 1 and K 2” must be set.

What is the warning when installing the clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

What must be done to the breather caps after removing the clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Pull off both breather caps -arrows- and close using suitable plugs to achieve an oil-tight seal.

What is the final step when removing the dual clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Remove clutch together with puller -T10373- .

What is the general note about cleaning the sealing surface on the gearbox and cover when renewing gear oil on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Clean sealing surface on gearbox and on cover.

What is the purpose of the cover fitted over the engaging levers in some vehicles when working on the mechatronic unit for the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

The cover prevents dirt getting in.

What is the torque setting for the cover fitted over the engaging levers on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Torque setting: 8 Nm.

What is the warning before starting the engine if the selector lever is shifted to position “N” at speeds above 5 km/h on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

When selector lever is shifted to position “N” at speeds above 5 km/h, solenoid for selector lever lock must not engage and block selector lever. Selector lever can be shifted into a driving range.

What warning is provided for the selector lever mechanism when working on the vehicle with the engine running on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

WARNING: Before working on vehicle with engine running, move selector lever into position “P” and apply handbrake.

What is the warning when removing the securing clip for the selector lever cable on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Securing clips for selector lever cable must always be renewed.

What must be done to the selector lever cable after installing it when removing and installing the selector mechanism for vehicles up to 02.2009 on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Adjust selector lever cable.

What is the note regarding the sealing grease when greasing the oil seal in the cover on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Grease oil seal in cover with sealing grease -G 052 128 A1- .

What should be done to the lever bolt when fitting the cover and lever again after renewing the oil seal in the cover on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Always renew bolt of lever. Fit cover and lever again. Attach lever again in same position.

What must be done when pressing the selector lever cable back onto the ball head and installing a new securing clip on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Press selector lever cable back onto ball head and install new securing clip. Securing clips for selector lever cable must always be renewed.

What is the warning regarding the selector lever positions when checking the selector mechanism on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

It must not be possible to start the engine in the selector lever positions “R”, “D” or “S”.

What should be done to the selector lever in the vehicle when adjusting the selector lever cable on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Move selector lever in vehicle to “P” position. Adjuster screw -arrow- must be “loosened”.

What is the warning about the selector lever symbols when the ignition and light are switched on for the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Symbols must change from “P R N D S” to “7 6 5 4 3 2 1”. The respective symbol in the shift mechanism cover lights up.

What general warning is associated with the selector mechanism when working on the vehicle with the engine running on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

WARNING: Before working on vehicle with engine running, move selector lever into position “P” and apply handbrake.

What is the required torque setting for the engaging lever bolts when installing the small engaging lever on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Screw on engaging lever with 2 new bolts. Torque setting: 8 Nm + 90°.

What is the note regarding the mounting for the engaging lever and entire mechanism of engagement bearing when installing the dual clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Mounting for engaging lever and entire mechanism of engagement bearing must be dry and free from oil or grease. If necessary, clean these components with a cloth.

What should be done to the selector lever handle before removal on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Before removal, pull lock button out past its pressure point. Secure locking button with a cable tie or wire against being pressed in. Unclip cover.

What is the warning when removing the selector lever handle on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Do not remove handle without reason. For emergency release, only the cover needs to be unclipped.

What is the warning regarding the gear actuators when installing the mechatronic unit on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Make sure that all 4 gear actuators project 25 millimetres -a-.

What is the warning regarding the gears and shafts in Repair Group 35 for the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Currently, no repairs can be made to gears and shafts.

What must be done to the mechatronic unit after removing it and before sending it for reconditioning on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Place plug on “removed” mechatronic unit if necessary. This way, the mechatronic unit can be sent sealed in oil-tight condition.

What must be done to the selector lever cable when installing the selector mechanism for vehicles from 03.2009 onwards on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Following installation, Bowden cable must be checked for ease of movement and be adjusted.

What must be done to the selector lever cable when checking its freedom of movement on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

If you remove the securing clip, you must always install a “new” securing clip.

What must be done to the selector lever cable when checking its freedom of movement on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Adjust cable.

What is the warning when installing the clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

What general caution should be observed regarding oil and grease when installing the dual clutch on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Caution: Do not oil or grease anything!

What is the note regarding the selector lever cable when checking its freedom of movement on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Do not grease connections of cable!

What is the note regarding the clutch when pulling it off after removing the retaining ring on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

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.

What must be done to the clutch before pulling it off after removing the retaining ring on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

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.

What is the note regarding the clutch when installing it on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

What is the note about the retaining ring’s installation position when inserting the new retaining ring after the clutch is pressed onto the stop on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Installation position of retaining ring: Joint of retaining ring is “narrower at top”. If you can insert retaining ring -arrow-, clutch is correctly pressed on to stop.

What is the torque setting for screwing on the engaging lever with 2 new bolts on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Torque setting: 8 Nm + 90°.

What must be done to the small engagement bearing shim when calculating the shim for clutch “K 2” on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Only insert small bearing. Do not insert any shim!

What must be done to the small engagement bearing to check its correct installation on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

By “turning”, check whether small engagement bearing is installed correctly and that grooves are seated correctly.

What is the warning when selecting the shim for clutch “K 2” on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

WARNING: Later on, only insert this 1 shim. Not 2 shims. This shim should be under small engagement bearing.

What is the final step for installing the selector mechanism after removing it when working on the selector mechanism for vehicles from 03.2009 onwards on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Install in reverse order of removal. Before you put on ball head: check cable. Install all parts of exhaust system which were removed. Install heat shield. Adjust selector lever cable after installing.

What is the warning when removing the selector housing when working on the selector mechanism for vehicles up to 02.2009 on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

Only leaking covers must be renewed. If the cover was not leaking, it does not need to be renewed.

What is the general warning regarding the clutch when installing it on the VOLKSWAGEN JETTA 2005 7-speed dual clutch gearbox 0AM?

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