Volkswagen Golf Variant 2007 User Manual

Service

Workshop Manual

Golf Variant 2007

Golf Variant 2010

Jetta 2005

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6-speed manualyV gearbox 0AJ

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Edition 07.2009th

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Service Department. Technical Information

Service

List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups

Repair Group

00 - Technical data

30 - Clutch

34 - Controls, housing

35 - Gears, shafts

39 - Final drive - differential

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Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R009620

		Golf Variant 2007 , GolfgVariant 2010 ,GJetta 2005
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											Contentsa
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00 - Technical data											e																						1b
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1	Gearbox identification				t p	e	r																										1
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1.1	Location on gearbox	s	n																														1		i
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1.2 Identification code, assemblylallocation and capacities																		.	. .	. .	. . . . .	.	. .	. .	.	.	.		. . . . .	.		.			s
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	Overview - power transmission				.		.				.		.	. .	. . . .	. . . . . .	.	. .	.	. . .	. . . .	. .	.	. . .		.	.	.	. . . .	.		.			t
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	Calculating overall gear ratiot “i”						.			.		.		. .	. . . . .	. . . . . .	.	. . .		. . .	. . . . .	.	. .	. . .		.	.		. . . . .	.		.
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4	General repair notes	r																															6		e
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4.1	Components	n																															6		c
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30 - Clutch		s
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	Fault finding, power transmission . . . . . . . .			.	. .		.	. . .		.	.	. . . . . . . . . .	. . .	. .		. . . .		. . .	.	. . . .
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	Repairing clutch mechanism m. . . . . . . . . . . .			.	.	.	.	. . .		.	.	. . . . . . . . . .	. . .	. .		. . . .		. . .	.	. . . .
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2.2 Assembly overview - pedal clustere . . . . . . .				.	.	.	.	. . .		.	.	. . . . . . . . . .	. .	. .		. . . .	.	. .	.	. . . .
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2.3 Removing and installing over-centrei spring .				.	.	.		. . .	.		.	. . . . . . . . . . .	. .	. .		. . . .	.	. .	.	. . . .
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2.4 Removing and installing clutch pedalo . . . . .			.	.	.	.		. . .	.	.	.	. . . . . . . . . . .	. .	. .		. . .	. .	. .	.	. . . .
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2.5 Removing and installing mounting brackety .			.	.	.		.	. . .	.		. .	. . . . . . . . . . .	. .	. .		. . .	. .	. .	.	. . . ..	n
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	Removing and installing master cylinder C... .			. .		.	.	. . .		.	.	. . . . . . . . . .	. .	. .	.	. . .	.	. .	.	.y. . .
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2.7 Removing and installing clutch position senderyG476																		b		i
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2.8	Assembly overview - hydraulics (LHD vehicles) . . .d.e								.		. .	. . . . . . . . . . .	. .	. .		.a.w.s	. .	. .	.	. . . .
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2.9 Assembly overview - hydraulics (RHD vehicles)													A	n
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2.10 Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3	Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	40
4	Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	42
4.1	Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	42
4.2	Removing and installing clutch release lever, release bearing and guide sleeve . . . . . . . .	43
5	Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	44

34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

1	Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	47
1.1	Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	47
1.2	Overview of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	48
1.3	Assembly overview - gear knob and frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	49
1.4	Removing and installing gaiter with gear knob and noise insulation . . . . . . . . . . . . . . . . . .	49
1.5	Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	51
1.6	Assembly overview - selector cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	57
1.7	Removing cable end-piece from relay lever and installing . . . . . . . . . . . . . . . . . . . . . . . . . .	59
1.8	Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	61
1.9	Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . .	65
1.10	Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	66
2	Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	70
2.1	Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	72
2.2	Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	79
3	Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	85
4	Checking gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	86
5	Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	88
5.1	Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	88
5.2	Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	89
5.3	Removing and installing cover for gearbox housing and 5th and 6th gear . . . . . . . . . . . .	90
5.4	Removing and installing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	92

Contents i

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

5.5	Removing and installing input shaft, output shaft, differential, selector mechanism and
	selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	93
5.6	Dismantling and assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	94
6	Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	107
7	Repairing gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	110
8	Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	113
9	Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	116

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

1	Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	121
1.1	Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	121
2	Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	131
2.1	Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	131

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

1	Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . .	139
1.1	Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	139
1.2	Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	140
2	Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	142
2.1	Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	142
2.2	Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	148

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ii Contents

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

00 – Technical data

1Gearbox identification

The 6-speed manual gearbox 0AJ is installed in the Jetta 2005 , in the Golf Variant 2007 and in the Golf Variant 2010 in con junction with a 4-cylinder injection engine.

Allocation page 1 .

1.1Location on gearbox

Code letters and date of gearbox manufacture -arrow-

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code and date of gearbox manufacture -arrow-

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Manufactured

from

P

.G

12.08

07.08

to

Allocation

Model

Jetta 2005 and Golf Var

Jetta 2005 , Golf Variant 2007 and

iant 2007

Golf Variant 2010

Engine

1.4 l - 90 kW

1.4 l - 90 kW

Ratio

Final drive

73 : 18 = 4.056

73 : 18 = 4.056

Z1 : Z2

Capacity of manual gearbox

2.0 l

2.0 l

Drive shaft flange

100 mm

100 mm

The following data can be found in the Electronic parts cata logue “ETKA” .

♦ Individual gear ratios

1. Gearbox identification 1

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

♦Gear oil

♦Clutch allocation

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2Rep. Gr.00 - Technical data

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

2Overview - power transmission

Designation

-Arrows- indicate direction of travel.

1 - Engine

2 - Clutch

3 - Manual gearbox

4 - Input shaft

5 - Output shaft

6 - Differential

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2. Overview - power transmission 3

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

I - 1st gear

II - 2nd gear

III - 3rd gear

IV - 4th gear

V - 5th gear

VI - 6th gear

R - Reverse gear

A - Final drive

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4Rep. Gr.00 - Technical data

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

3Calculating overall gear ratio “i”

Example:

	6th gear	Final drive
Drive gear	ZG1 = 49	ZA1 = 15
Driven gear	ZG2 = 38	ZA2 = 76

i = Z2 : Z1 1)

iG = Gear ratio = ZG2: ZG1= 38 : 49 = 0.776

iA = Final drive ratio = ZA2 : ZA1 = 76 : 15 = 5.067 itotal = Overall ratio = iG x iA = 0.776 x 5.067 = 3.932

1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear

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3. Calculating overall gear ratio “i” 5

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

4General repair notes

To ensure perfect and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential. Of course, the basic rules for safety also apply dur ing repair work.

AnumberofinstructionsgenerallyapplicabletothevariousrepairA

o

procedures - which were previously repeated a numberl

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of times

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under

at various places in the workshop manual are summariseddb

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the topic “components” page 6 . They apply to this workshop

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4.1

Components

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4.1.1

Gearbox

t

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,

gearbox, ensure that the dowel

♦ When installing the manualo

e

l

andgearboxarecorrectlyseated.

sleevesbetweentheenginew

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i

♦ When installing mountingo brackets or waxed components,

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clean the contact surfaces. Contact surfaces must be free of

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r

wax and grease.

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♦ Following installation, check gear oil level page 86 .

e

s

♦ Capacity page 1 .

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4.1.2

l

O-rings, seals and gaskets

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♦ Always renew O-rings,

seals and gaskets.

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o

♦ Before installing oil seal, half-fill space between sealing lips

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e

with sealing grease -G 052 128rA1- -arrow-.

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♦ The open side of the oil seal facesgthe side with fluid filling.

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♦ Following installation, check gear oil level page 86 .

p

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the rings be

♦ Lightly oil O-rings before installing; this preventspo

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ing crushed when inserted.

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♦ Thoroughly clean parting surfaces and apply sealant -AMV

188 200 03- .

♦ Apply sealant uniformly but not too thick.

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4.1.3Sealant

♦Thoroughly clean housing joint surfaces before applying seal ing paste.

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

♦Breather holes must remain free of sealing paste.

6Rep. Gr.00 - Technical data

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

4.1.4Locking devices

♦Always renew retaining rings which have been damaged or overstretched.

♦Do not overstretch retaining rings.

♦Retaining rings must locate properly in grooves.

♦Renewspringpins.Installationposition:slotlongitudinaltoline of force.

4.1.5Nuts and bolts

♦ Loosen and tighten securing bolts and nuts for covers and

housings diagonally.

♦ Do not cant especially delicate parts, such as clutch pressure

plates. Loosen and tighten bolts and nuts in stages in a diag

onal sequence.

♦ Torque settings are specified for unoiled bolts and nuts.

♦ Always renew self-locking bolts and nuts.

♦ Ensure with threaded connections that contact surfaces as

well as nuts and bolts are rewaxed only after assembly, if nec

essary.

♦ Threads of bolts secured with lockings

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fluid must be cleanede

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with a wire brush. Then insert bolts with locking fluid AMV 185g

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♦ All threaded holessinto which self-locking bolts are to be

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screwed must ben cleaned of residual locking fluid using a

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thread chaser. dOtherwise there is a danger of bolts shearing

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when subsequently being removed.

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4.1.6

Bearings

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♦ Install newl

tapered roller bearings as supplied and do not lu

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bricate additionally.h

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bearings with lettered side (thicker metal) to

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♦ Install needleo

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wardsrfitting tool.

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♦ Taperedrollerbearingsfittedtooneshaftmustberenewedas

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same make of bearings.

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♦ Heat bearing inner races to max. 100° C with the inductive

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heater -aVAS 6414before installing.

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♦ Do not

interchange outer or inner bearing races of the

same

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size. Thembearings are matched in pairs.

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4. General repair notes 7

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

4.1.7Shims

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

o

♦

Check for burrs and damage.

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♦

Install only flawless shims.

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4.1.8

o

-rings

Synchros

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When reusing synchro-rings, always fit to

♦ Do not interchange.ho

w

the same gear.

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t

♦ Check forrwear and renew if necessary.

a

p

n

i

♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for

,

s

flat spotse(worn grooves).

s

o

p

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

u

p

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a

i

♦ If an intermediate ring -B- is installed, check the outer friction

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surface -arrow 2- and inner friction surface -arrow 3- of this

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intermediate ring for “scoring”, “signs of abnormal wear” and

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“blue discolouration (due to overheating)”.

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♦ Ifthesynchro-ringsarecoated,checkconeofsynchromeshed

v

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gear for “scoring”rand “signs of abnormal wear”.

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♦ Moisten synchromeshn mechanism with gear oil before instal

ling.

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4.1.9Gear wheels

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

4.1.10Synchromeshed gears

♦Afterassembly,checksynchromeshedgearsforslightplay,or for freedom of movement.

4.1.11Clutch

♦Ensurethatthepressureplatedoesnotcant:loosenandtight en bolts diagonally and in several gradual stages.

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

♦When removing gearbox, remove slave cylinder without dis connecting pipes.

♦If the clutch slave cylinder is removed with the hydraulic line attached, do not depress clutch pedal. Otherwise the piston will be pressed out of the slave cylinder.

i l i t

y

w

i t

h

r e

8Rep. Gr.00 - Technical data

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

30 – Clutch

1Fault finding, power transmission

Please note:

♦Faultfinding,powertransmission;Rep.Gr. 30;Complaints regarding clutch and clutch actuation

♦Faultfinding,powertransmission;Rep.Gr. 34;Complaints regarding selector mechanism

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1. Fault finding, power transmission 9

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

2Repairing clutch mechanism

2.1Overview

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A

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♦ Before disconnecting battery, obtains code for radio units having anti-theft coding.

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♦

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

necting battery .

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♦

When reconnecting battery,

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battery .

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♦

Lubricate all bearings ando contact surfaces with grease -G 000 450 02- .

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h

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a

I - Assembly overview - pedalp

cluster page 11

n

i

,

s

e

s

II - Assembly overview - hyo

draulics (LHD vehicles)

p

r

page 35

u

p

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a

i

c

r

III - Assembly overview - hy e

draulics (RHD vehicles)

m

m

page 37

o

c

r

10 Rep. Gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

2.2Assembly overview - pedal cluster

1 - Bulkhead

With support for mount ing bracket

2 - Seal

Always renew

Between mounting bracket and bulkhead

Self-adhesive

Bond to mounting bracket

3 - Mounting bracket

For mounting clutch pedal

Is provided with damp ing in some equipment variants page 12

Removing and installing

page 23

4 - Bolt

5 - Over-centre spring

Removing and installingpage 12

6 - Bearing bush

7 - Pivot pin

8 - Clutch pedal

Removing and installingpage 17

9 - Retainer

To remove and install,

separate master cylin

der from clutch pedal

r

c

“2.4 Removing and installing clutch pedal”, page 17

e

m

10 - Seal

m

r

o

Always renew

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t

d

Between master cylinder and mountingr

bracket

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i

p

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f

11 - Master cylinder

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bracket page 29

Removing and installing after removal of mounting.t

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12 - Clutch position sender -G476-

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Removing and installing page 31

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orP

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n

Can be checked using “guided fault finding” of vehicle diagnostic tester

The clutch position sender -G476- is identified as clutch pedal switch -F36- in “guided fault finding”

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i

n

s p e c t

t o

t h e

c o r r e c t n e s s o f i n f o r

oitam

13 - Clip

Pull out clip to stop to remove and install pipe/hose line or plastic line

14 - Supply hose

Made of plastic page 36 15 - Hexagon nut, 25 Nm

Self-locking

Qty. 3

2. Repairing clutch mechanism 11

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

For mounting bracket on bulkhead

Always renew

16 - Hexagon nut, 25 NmAlways renew

17 - Stop

For clutch pedal

Mounting bracket with damping -arrows-

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12 Rep. Gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

2.3.1Removing

Vehicles with knee airbag

Note

The installation location of the knee airbag is above the pedal cluster.

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– First check whether a coded radio is fitted. If so, obtain anti-

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battery Electrical sys

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body repairs, interior;wRep. Gr. 68 .

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Continuation for all

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Remove footwell vent -m3-

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Gr. 80 ; Repairing heating .

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The crash bar -1- in front of clutch pedal -2- may be secured in different ways.

Attachment with 2 bolts

– Remove crash bar -1- (2 bolts).

2. Repairing clutch mechanism 13

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

Attachment with 1 bolt

– Remove crash bar -1- (1 bolt -2-). Continuation for all

If fitted, remove damping -arrow- from lowerG.

areaag of clutch pedal

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mounting bracket.

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14 Rep. Gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

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

–Unboltclutchpedal-1- frommountingbracket-3- byremoving nut -2- and pulling out bolt -5-.

Note

The clutch pedal remains hooked to operating rod of master cyl inder.

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

2.3.2Installing

Install in the reverse order of removal,

Note

Renew self-locking nuts.

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Repairingaclutch mechanism

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

–Insert over-centre spring -2- in mounting bracket from above while holding end of spring with assembly tool -T10178- in in stallation position.

•Receptacle -arrow- for tip -A- of clutch pedal must stand ver tically.

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

–Depress clutch pedal slightly, push bolt through and tighten self-locking nut to specified torque page 17 .

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Some cars have damping -arrow- on the clutchspedal mounting

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Vehicles without knee airbag

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

The crash bar -1- in front of clutch pedal -2- may be secured in different ways.

Attachment with 2 bolts

–Install crash bar -1- and tighten the 2 bolts to specified torquepage 17 .

Attachment with 1 bolt

–Install crash bar -1- and tighten bolt -2- to specified torquepage 17 .

Continuation for all

– Mount cable guide -2- on steering column.

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–

Install footwell vent -3-sw

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Heating, air conditioning;oe

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80 ; Repairing heating .

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Vehicles with knee airbag

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Install bracketle

for knee airbag together with crash bar Gen

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repairs,interior;Rep.Gr. 69;Airbag;Removingand

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knee airbag bracket .

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for all

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,iInstall trim and cover below trim on drive side General body

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68 .

repairs, interior; Rep. Gr.

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Reconnectbatteryandperformworkrequiredafterconnecting

–i

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battery Electrical system; Rep. Gr. 27 ; Disconnecting and

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connecting battery .

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Torque settings

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Component

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Crash bar to steering column mounting

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bracket (attachment with 2 bolts)

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Crash barfto steering column mounting

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bracket (attachment with 1 bolt)

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Special tools and workshop equipment required

2. Repairing clutch mechanism 17

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

♦ Pliers -T10005-

♦ Release tool -T10178-

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Torque wrench -V.A.G 1331-

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2.4.1

Removing

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Vehicles with knee airbag

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Note

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or

– First check whether a coded radio is fitted. If so, obtain anti-

P

theft code.

– With ignition switched off, disconnect battery earth strap Electricalsystem;Rep.Gr. 27;Disconnectingandconnecting battery .

Continuation for all

–Pushdriverseatasfarbackaspossibleandputsteeringwheel in highest position.

–Remove trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 .

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18 Rep. Gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

Vehicles with knee airbag

–Remove bracket for knee airbag together with crash bar Generalbodyrepairs,interior;Rep.Gr. 69;Airbag;Removing and installing knee airbag bracket .

Continuation for all

–Remove cable guide -2- from steering column.

–Remove footwell vent -3- Heating, air conditioning; Rep. Gr. 80 ; Repairing heating .

Vehicles without knee airbag

e

d

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Attachment with 1 bolt

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– Remove crash bar -1- (1 bolt -2-). h

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Continuation for all

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The crash bar -1- in front of clutch pedal -2- may be secured in

different ways.

Attachment with 2 bolts

– Remove crash bar -1- (2 bolts).

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2. Repairing clutch mechanism 19

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

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

–To do this, remove lock washers -A- for damping.

–Pull off damping.

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– Push damping upwards in area of upper securingo

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above clutch pedal -A- in -direction of arrow-. is

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Rep. Gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

–Unboltclutchpedal-1- frommountingbracket-3- byremoving nut -2- and pulling out bolt -5-.

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

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2.4.2

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Installings

,

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Install in the reverse orderpof removal, observing the following:

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Renew self-locking nuts.

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operating rod -1-.

– Attach retainer -2- to master cylinderf

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2. Repairing clutch mechanism 21

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

–Insert over-centre spring -2- in mounting bracket from above while holding end of spring with assembly tool -T10178- in in stallation position.

o

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oReceptacle -arrow- for tip -A- of clutch pedal must stand ver

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a tically.

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, Insert tip -A- of clutch pedal in bearing recess of over-centre

s

e

sspring.

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o

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aself-locking nut to specified torque page 23 .

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–

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22 Rep. Gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

The crash bar -1- in front of clutch pedal -2- may be secured in different ways.

Attachment with 2 bolts

–Install crash bar -1- and tighten the 2 bolts to specified torquepage 23 .

Attachment with 1 bolt

Continuation for all

–Install crash bar -1- and tighten bolt -2- to specified torquepage 23 .

Continuation for all

–Mount cable guide -2- on steering column.

–Install footwell vent -3-. Heating, air conditioning; Rep. Gr. 80 ; Repairing heating

Vehicles with knee airbag

–

Install bracket for knee airbag together with crash bar GenenAG.Vo

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eralbodyrepairs,interior;Rep.Gr. 69;Airbag;Removingand

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installing knee airbag bracket .

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Continuation for all

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–

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Install trim and cover below trim on driven side General body

le

repairs, interior; Rep. Gr. 68 .

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requiredafterconnecting

– Reconnectbatteryandperformworke

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battery Electrical system; Rep.oGr. 27 ; Disconnecting and

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Clutch pedal to mounting bracket

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♦

Renew self-locking nuts

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Crash bar to steering column

mounting

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bracket (attachment with 2 bolts)c

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Crash bar to steering column mounting

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bracket (attachment with 1 bolts)

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2. Repairing clutch mechanism 23

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

♦ Hose clamps to 25 mm -3094-

♦ Torque wrench -V.A.G 1331-

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2.5.1Removing

Left-hand drive

–First check whether a coded radio is fitted. If so, obtain antitheft code.

c e p t a

i n f o r

24 Rep. Gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

– With ignition switched off, disconnect battery earth strap Electricalsystem;Rep.Gr. 27;Disconnectingandconnecting battery .

– Remove complete air filter housing if it is locatedVolksclosew

to the

G.

ag

battery

Rep. Gr.

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en

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24 ; Repairing injection system .

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– Remove battery and batterystray Electrical system; Rep.

a

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t

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e

th

e

Gr. 27 ; Battery; Removing and installing battery .

o

u

r

a

a

Continuation for all

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s

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t

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Note

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p

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work, ensure that no brake fluid lands on

♦ During the following,i

e

orgearbox.Ifthisdoeshappen,cleanthe

l

longitudinalmembero

h

thoroughly.

affected areasw

n

i

r

♦ Place a linto-free cloth under the master cylinder.

t

r

a

p

n

i

,

– Clamp off supply hose to master cylinder using hose clamp

-3094- .

s

e

s

o

p

r

u

– If necessary, loosen spring-type clip -3- with hose clip pliers -

p

l

VAS 6362-aand pull supply hose off master cylinder.

i

c

r

e

m

– In addition, sealm supply hose with sealing tool -T10249/1- .

o

c

r

o

– Release securing clip -2- using screwdriver or pointed object

e

t

a

and pull pipe/hose line or plastic line -1- off master cylinder.

v

i

r

p

r

– Unclip clutch positiono sender -G476- from master cylinder

f

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n

-arrow- and remove with electrical connector attached -4-.

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Note

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et

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or

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When performing work in the footwell, put cloths on the carpet to

protect it from possible brake fluid spills.

–Remove trim and cover below trim on drive side General body repairs, interior; Rep. Gr. 68 .

Vehicles with knee airbag

Note

The installation location of the knee airbag is above the pedal cluster.

–Remove bracket for knee airbag together with crash bar Generalbodyrepairs,interior;Rep.Gr. 69;Airbag;Removing and installing knee airbag bracket .

Continuation for all

i n f o r m

2. Repairing clutch mechanism 25

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 6-speed manual gearbox 0AJ - Edition 07.2009

– Remove cable guide -2- from steering column.

– Remove footwell vent -3- Heating,a

air conditioning;d

Rep.

o

G.

V

lksw

ag

en

en

A

A

G

Gr. 80 ; Repairing heating .

w

g

o

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s

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o

V

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y

b

u

d

a

e

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Vehicles without kneeoairbag

a

s

i

n

th

r

t

e

o

u

r

a

a

s

s

le

d

u

n

e

t

t

m

i

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p

e

t

o

n

s

i

,

e

l

o

h

w

bar -1- in front of clutch pedal -2- may be secured in

The crashr

n

i

differentr ways.

o

t

a

Attachment with 2 bolts

p

n

i

,

s

crash bar (2 bolts).

– Unbolts

e

o

p

with 1 bolt

Attachmentp

r

u

l

a

i

c

r

e

m

m

o

c

r

o

e

t

a

v

i

r

p

r

o

f

– Remove crash bar -1- (1 bolt -2-).

g

n

i

p

C

y

o

o

Continuation for all

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p

gi

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t

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y

b

p

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y

V

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b

d

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w

a

g

c

et

e

or

P

A

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e

m

u

e c

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

26 Rep. Gr.30 - Clutch