Volkswagen Golf Variant 2008 User Manual

Service

Workshop Manual

Jetta 2006

Golf Variant 2008

5-speed manual gearbox 0AF

Edition 08.2007

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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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All rights reserved.

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No reproduction without prior agreement from publisher.

Copyright © 2010 Volkswagen AG, Wolfsburg

MEX5R007420

Jetta 2006 , Golf Variant 2008 5-speed manual gearbox 0AF - Edition 08.2007

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1	Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1
1.1	Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1
1.2	Identification codes, assembly allocation, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1
2	Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3
3	Calculating overall gear ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
4	General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6
4.1	Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6

30 - Clutch . . . . . . . . . . . . .			.				.			.		.	.	. . . .			.	.		.	. .		.	.		.	.	. . . . . . .	. .	.	.		.	.		.		.	.		.		.	.	. .	. .		.			.			.		.				9
1	Fault finding, Power transmission														.		.	.		. .	.	. .		.	.		. .	. . . . . . . .	. .	.	.	.	.	.		.	.	.		. .		.		.	. . .	. .	.			.	.			.		.				9
2	Repairing clutch mechanism													. . . .	.		.	.		. .	.	. .		.	.		. .	. . . . . . . .	. .	.	.	.	.	.		.	.	.		. .		.		.	. . .	. .	.			.	.			.		.				10
2.1	Overview . . . . . . . . .			.			.			.		.	. .	. . . .	.			.	.	.	. .	.	.	.			. .	. . . . . . . . .	. .		. .		.	.	.		. .			. .		.		.	. . .	. .	.		.	.				.		.				10
2.2	Assembly overview - pedal cluster															.		.	.	.	. .	.	.	.		.	.	. . . . . . . . .	. .	.	.	.	.		. .		. .			. .			.	.	. . .	. .	.		.	.				.		.				11
2.3	Removing and installing over-centre spring .																							.		.	.	. . . . . . . . .	. .	.	.		.	.	.		. .		.	.		.		.	. . .	. .	.		.	.				.		.				12
2.4	Removing and installing clutch pedal																		.	.	. .	.	.	.		.	.	. . . . . . . . . .	.	.	.	.	.		. .		. .			. .			.	.	. . .	. .	.		.	.				.		.				14
2.5	Removing and installing mounting bracket																					.	.	.			. .	A..G. .V..o..lk..s..w..ag. ..e.n.		.	.	.	.		. .		. .			. .			.	.	. . .	. .	.		.	.				.		.				16
2.6	Removing and installing master cylinder																				.	. .		.		.	e.n.			A.	G.	d.		.	.	.	.		.	.		.		.	. . .	. .	.		.	.				.		.				19
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2.7																								a		G476											o.t																							21
	Removing and installing clutch position senderV																												.	.	.			e.	.				.	.		.		.	. . .	. .	.		.	.				.		.
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2.8	Assembly overview - hydraulic system																			y	o																		g	u																				24
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2.9														r																														t	r															25
	Removing and installing slave cylinder																			.	. .	.		.	.		. .	. . . . . . . . . .		.	. .		.	.	.		. .			. .		.		.		. .	.		.	.				.		.
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2.10	Bleeding clutch system							. . .l.e						a																																														27
														.s. . .	.		.	.		. .	.	. .		.	.		. .	. . . . . . . . . .		.	.	.	.	.	.		. .			. .		.		.	. . .	e. .	.		.	.				.		.
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	Repairing clutch release mechanismd																		.	.	. .	. .		.		.	. .	. . . . . . . . .	.	.	.	.	.	.	.		. .			. .			.	.	. . .	. .	.	y. .						.		.
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4	Repairing clutch . . . . .r							m																																										i										31
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34 - Controls, housing . . . .is			o																																																			y				34
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1	e																																																								s			34
	Fault finding, Powerotransmission														.		.	.		. .	.	. .		.	.		. .	. . . . . . . . . .		.	.	.	.	.	.		. .			. .		.		.	. . .	. .	.		.	.				.		.	p
	l
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	Repairing selector imechanism . . .															.		.	.	.	. .	.		. .			. .	. . . . . . . . . .		.	. .		.	.	.		. .			. .		.		.	. . .	. .	.		.	.				.		.				35
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2.1	Installation positiont of selector mechanism																																																									o
																						.		.	.		. .	. . . . . . . . .	.	.	.	.		.	.	.	.		.	.		.		.	. . .	. .	.		.	.				.		.		h35
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2.2	r																																																									e
	Removing and installing selector lever knob and cover . . . . .																												.	.	.	.	.	.	.		. .			. .			.	.	. . .	. .	.		.	.				.		.				38
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2.3	n																																																											38
	Removing and installing gaiter with selector lever knob and noise insulation																																											.	. . .	.	.	.		.				.		.
	i																																																										r
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2.4	s																																																											c
	Repairing selectorolever and selector lever housing (through 10.06)																																	.	.		. .			. .			.	.	. . .	. .	.		.	.				.		.			e40
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2.5	p																																																									s
	Repairing selector lever and selector lever housing (from 11.06)																														.		.	.	.		. .		.	.		.		.	. . .	. .	.		.	.				.		.		o42
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	u																																																									f
2.6	p
	Assembly overviewi- removing and installing selector cables .																													.	.	.	.		. .		. .			. .			.	.	. .	. .	.		.	.				.		.	f			47
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2.7																																																									o			50
	r
	Plastic relay lever .e.	.			.			.			.	.	. .	. . . .			.	.	.	.	. .	.		.	.		. .	. . . . . . . . . .		.	. .		.	.	.		. .			. .		.		.	. . .	. .	.		.	.				.		.
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2.8	Removing and installingo selector mechanism																																																								a			51
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2.9	c																																																						n					54
	Adjusting selector mechanism													. . .	.			.	.	.	. .	.	.	.			. .	. . . . . . . . . .	.		. .		.	.	.		. .			. .		.		.	. . .	. .	.		.	.				.		.
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3	Removing and installing gearbox .														.			.	.	.	. .	.	.	.			. .	. . . . . . . . . .	.		. .		.	.	.		. .			. .		.		.	. . .	. .	.		.	.	d	s	i	.		.				57
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3.1								i																																								u												59
	Removing gearbox . . . . . o. . .													. . . .		.		.	.	.	. .	.	.	.		.	.	. . . . . . . . . .	.	.	.	.	.		. .		. .			. .			.	.	. . .	. .	.		c .	.				.		.
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3.2	Transporting gearbox											r																																		e														64
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3.3	Installing gearbox													y																														y																65
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3.4	Torque settings													t			r.y																							b																				70
			.			.		.				. .	.	. . . .h.						. .	.	. .		.	.		. .	. . . . . . . . . .		.	.	.	.	.	.		. .						g.		. . .	. .	.		.	.				.		.
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4	Checking gear oil																			c	y	de.t										ga.w					o																							72
		.		.			.				.	.	. .	. . . .		.		.	.	.				. .			. .	. . . . . . . . . .		.	. .					kl. .				. .		.		.	. . .	. .	.		.	.				.		.
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5	Dismantling and assembling gearbox																										P		. G																															74
																				. .	.	. .		.	.		. .	. . . . . . . . .	.	.	.	.		.	.	.	.		.	.		.	.		. . .	. .	.		.	.				.		.
5.1	Overview - gearbox .			.		.			.			. .	.	. . . .	.			.	.	.	. .	.	.	.			. .	. . . . . . . . . .	.	.	.		.	.	.		. .		.	.		.		.	. . .	. .	.		.	.				.		.				74
5.2	Assembly overview .		.		.			.				. .	. .	. . . .			.	.	.	.	. .	.	.	.			. .	. . . . . . . . . .	.	.	.	.	.		. .		. .			. .			.	.	. . .	. .	.		.	.				.		.				75
5.3	Assembly overview - removing and installing cover for gearbox housing and 5th gear . . . .																																																											76
5.4	Assembly overview - removing and installing clutch housing .																												.	.	.	.	.		. .		. .			. .			.	.	. . .	. .	.		.	.				.		.				77
5.5	Assembly overview - removing and installing input shaft, output shaft (drive pinion),																																																											78
	differential, selector mechanism and selector forks . . . . . . . .																												.	.	.	.		.	.	.	.		.	.		.	.		. . .	. .	.		.	.				.		.
5.6	Dismantling and assembling procedure																				. .	. .		.		.	. .	. . . . . . . . .	.	.	.	.	.		. .		. .			. .			.	.	. . .	. .	.		.	.				.		.				79

Contents i

Jetta 2006 , Golf Variant 2008

5-speed manual gearbox 0AF - Edition 08.2007

6	Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	89
7	Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	94
8	Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	97

35 - Gears, shafts . . . .			.			.		.		.	.	. .	.		.		.	.		.	.		.	.		.	.	.		. .	.o. .	.	.	.	.		.	.		.	.		.		.	.	.		.	. .	. .	.			.			.			.		. . . .	102
																														G .	V lksw
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1	Input shaft																					l.ks.w					en		A						A		G	d	oe.s																									102
			.		.		.		.		. .	. . .		.		.	.	.		.	.					.			.	. .	. . . .	. .		.								.	.		.	.	.	.		. . .	. .	.		.	.				.	.			. . . . .
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																				V																										a																		102
1.1 Dismantling and assembling input shaft																										.	.	.	.	.	. . . . .	. .		.	.		. .		.	.	.		.	.	g		.		.	. . .	. .	.		.		.			.	.			. . . . .
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2	Output shaft											t		r																																			t	o														113
		.		.	.		.			.	.		o. .			.		.	.	.	.		.	.	.	.	.	.	.	.	. . . . .	.		. .	.		.	.		.	.	.	.		.	.	.	.	.		. .	.	.		.			.		.			. . . . .
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												a		output shaft																																				a														113
2.1 Dismantling and assemblings																											.	.	. .		. . . . . .			. . .			.	.	.	.		.	.		.	.	.	.	.	. . .	e.	.	.		.		.			.			. . . . .
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39 - Final drive - differentiali									d																																											a			a									120
										.	.	. .	.		.	.		.		.	.		.	.		.	.	.	. .		. . . . .			. . .			.		.	.		.	.		.	.		.	.	. . .	.		.							.			. . . .
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ii Contents

Jetta 2006 , Golf Variant 2008 5-speed manual gearbox 0AF - Edition 08.2007

00 – Technical data

1Gearbox identification

The 5-speed manual gearbox 0AF is installed in the Jetta 2006 and Golf Variant 2008 in conjunction with a 4-cylinder engine.

Allocation page 1

1.1Location on gearbox

Code letters and date of manufacture -arrow 1- Manual gearbox 0AF -arrow 2-

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Manual gearbox 0AF -arrow 2-

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Identification code and date of gearbox manufacture -arrow-

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Example:

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1.2Identification codes, assembly allocation, capacities

Manual gearbox			5-speed 0AF
Identification code		FVH	JHT
Manufac	from	05.05	11.06
tured	to
Allocation	Model	Jetta 2006	Jetta 2006
		Golf Variant 2008	Golf Variant 2008

1. Gearbox identification 1

Jetta 2006 , Golf Variant 2008

5-speed manual gearbox 0AF - Edition 08.2007

Manual gearbox			5-speed 0AF
Identification code		FVH	JHT
	Engine	1.6 l - 75 kW	1.6 l - 75 kW
Ratio	Final drive	68 : 15 = 4.533	68 : 15 = 4.533
Z1 : Z2
Capacity of manual gear		2.0 l	2.0 l
box
Drive shaft flange		100 mm	100 mm

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

♦Individual gear ratios

♦Gear oil

♦Clutch allocation

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2Rep. Gr.00 - Technical data

Jetta 2006 , Golf Variant 2008 5-speed manual gearbox 0AF - Edition 08.2007

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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Gears

-Arrows- indicate direction of travel.

2. Overview - power transmission 3

Jetta 2006 , Golf Variant 2008

5-speed manual gearbox 0AF - Edition 08.2007

I - 1st gear

II - 2nd gear

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III - 3rd gear

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IV - 4th gear

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4Rep. Gr.00 - Technical data

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Example:

Drive gear

Driven gear

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gear ratio “i”

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5th gear

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ZG = 49

ZA = 16

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ZA2 = 67

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i = Z			: Z	1	1)	n
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		2				,
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						s
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						p
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i		= Overall ratio = i		e	= 0.776 x 4.188 = 3.250
	total		G	mA

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

Jetta 2006 , Golf Variant 2008

5-speed manual gearbox 0AF - Edition 08.2007

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 isessential.Ofcourse,thebasicrulesforsafetyalsoapplyduring repair work.

Anumberofinstructionsgenerallyapplicabletothevariousrepair procedures - which were previously repeated a number of times at various places in the workshop manual are summarised under the topic “components” page 6 . They apply to this workshop manual.

4.1Components

4.1.1Gearbox

♦ When installing the manual gearbox, ensure that the dowel

sleevesbetweentheengineandgearboxarecorrectlyseated.

o

G.

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ag

en

A

♦ When installing mounting brackets or waxed components,

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clean the contact surfaces. Contact surfaces must be free ofu

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wax and grease.

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♦ Allocate bolts andsother components using Electronic parts

c

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a

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c

catalogue “ETKA”n

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a gearbox, fill with gear oil to lower edge of

a

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♦ When changingi

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filler hole.

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♦ Capacitiesn

page 1

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4.1.2

,

Seals and sealing rings

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

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with sealing grease -G 052 128 A1- -arrow-.

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♦ After

p

,installing, check oil level page 72 .

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clean parting surfaces and apply sealant -AMV

♦ Thoroughlyo

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188 200 03- .

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♦ Apply sealant uniformly but not too thick.

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4.1.3

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Lockingo devices

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♦ Renew retaining rings.

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♦ Do not overstretch retaining rings.etc

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♦ Retaining rings must locate properly in grooves.

♦ Renewspringpins.Installationposition:slotlongitudinaltoline

of force.

6Rep. Gr.00 - Technical data

Jetta 2006 , Golf Variant 2008 5-speed manual gearbox 0AF - Edition 08.2007

4.1.4Nuts 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.

♦Use a thread chaser to clear residual locking fluid from all threadedholesintowhichself-lockingboltsaretobescrewed. Otherwise there is a danger of bolts shearing when subse quently being removed.

4.1.5Bearings

♦Install new tapered roller bearings as supplied and do not lu bricate additionally.

♦Install needle bearings with lettered side (thicker metal) to wards fitting tool.

♦Taperedrollerbearingsfittedtooneshaftmustberenewedas a set. Use same make of bearings.

♦Heat inner races to about 100° C with the inductive heater - VAS 6414before installing.

♦Do not interchange outer or inner races of bearings of the same size. The bearings are matched in pairs.

4.1.6

Shims

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♦ Measure shims at several points with a micrometer.i

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ious thicknesses make it possible to achieve the exact shim

thickness required.

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♦ Check for burrs and damage.

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♦ Install only flawless shims.

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4.1.7

Synchro-rings

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♦ Do not interchange. When reusingo synchro-rings, always fit to

the same gear.

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♦ Check for wear and renew if necessary.

r

a

-ring -A- and inner ring for

p

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♦ Check grooves -arrow 1- of synchroi

flat spots (worn grooves).

,

s

e

s

must not be damaged.

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p

♦ If synchro-rings are coated, coatingr

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p

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a

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

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

m

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

m

o

“blue discolouration (due to overheating)”.

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r

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t

♦ Check cone of synchromeshed gear for “scoring” and “signs

of abnormal wear”.

a

v

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r

p

r

o

f

g

♦ Moisten synchromesh mechanism with gear oil before instal

ling.

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

4. General repair notes 7

Jetta 2006 , Golf Variant 2008

5-speed manual gearbox 0AF - Edition 08.2007

4.1.8Gear wheels

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

4.1.9Synchromeshed gears

♦Afterassembly,checksynchromeshedgearsforslightplay,or for freedom of movement.

4.1.10Clutch

♦ Ensurethatthepressureplatedoesnotcant:loosenandn

tight

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en bolts diagonally and in severalo gradual stages.

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♦ If the clutch has burnt out,rthoroughly clean the bell housing

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as well as the friction surface of flywheel with a cloth to reduce

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the smell of burnt linings.s

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8Rep. Gr.00 - Technical data

Jetta 2006 , Golf Variant 2008 5-speed manual gearbox 0AF - Edition 08.2007

30 – Clutch

1

–

Fault finding, Power transmission

.

Refer to Fault finding, power transmission;sRep. Gr.

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Complaints about clutch and clutch mechanism and

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finding, power transmission; Rep. Gr. 34 ; Complaints

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1. Fault finding, Power transmission 9

Jetta 2006 , Golf Variant 2008

5-speed manual gearbox 0AF - Edition 08.2007

2Repairing clutch mechanism

2.1Overview

Note

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

o

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en

♦ With ignition switched off, disconnectl

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A

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battery earth strap.

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Electrical system; Rep.rGr. 27 ;Disconnecting and connecting batteryt

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♦

refer to Electrical system; Rep.Gr. 27 ;Disconnecting and connecting

When reconnecting battery,s

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a

battery .

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♦

d

and contact surfaces with grease -G 000 450 02- .

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I - Assembly overview,

- pedal

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cluster page o11

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II - Assembly overviewi

n

draulics paget 24

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10 Rep. Gr.30 - Clutch

Jetta 2006 , Golf Variant 2008 5-speed manual gearbox 0AF - Edition 08.2007

2.2Assembly overview - pedal cluster

1 - Bulkhead

With support for mount

V

ing bracket

e

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is

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2 - Seal

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bracket

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Removing and installing

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16

pages

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4 - Bolt p

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5 - Over-centre spring

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Removing and installing

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page 12

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6 - Bearing bush

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7 - Pivot pin

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8 - Clutch pedal

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Removing and installing

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page 14

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9 - Retainer

To remove and install, separate master cylin der from clutch pedal.page 14

10 - Seal

Always renew

Between master cylinder and mounting bracket

11 - Master cylinder

Removing and installing after removal of mounting bracket page 19

12 - Clutch position sender -G476-

Removing and installing page 21

Can be checked in “guided fault finding” of vehicle diagnosis, testing and information system -VAS 5051-

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

13 - Clip

Pull out clip to stop to remove and install pipe/hose line or plastic line 14 - Supply hose

Rubber

From 12.05, plastic in some vehicles page 25

15 - Self-locking hexagon nut, 25 Nm

Qty. 3

For mounting bracket on bulkhead

Always renew

2. Repairing clutch mechanism 11

Jetta 2006 , Golf Variant 2008

5-speed manual gearbox 0AF - Edition 08.2007

16 - Hexagon nut, 25 NmAlways renew

17 - Stop

For clutch pedal

2.3Removing and installing over-centre spring

Special tools and workshop equipment required ♦ Release tool -T10178-

2.3.1Removing

–

Pushdriverseatasfarbackaspossibleandputsteeringwheel

AG.

in highest position.

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–

Remove trim and cover below trim on drive side

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General

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body repairs, interior; Rep. Gr. 68 .

r

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a

s

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– Now unbolt crash bar -1- from in front ofnclutch pedal -2-.

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12 Rep. Gr.30 - Clutch

Jetta 2006 , Golf Variant 2008 5-speed manual gearbox 0AF - Edition 08.2007

–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, observing the following:

Note

Renew self-locking nuts.

– Insertover-centrespringinmountingbracketfromaboveewhile

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holding end of spring with release tool -T10178- inoinstallation

a

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position.

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– Insert tip of clutch pedal in bearing recessa

of over-centre

th

spring.

u

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le

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– Depress clutch pedal slightly, pushe

u

n

bolt through and tighten

self-locking nut.

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– Now bolt on crash bar -1- in front of clutch pedal -2-.

m

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– Install trim and cover below trimoon drive side General body
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2. Repairing clutch mechanism 13

Jetta 2006 , Golf Variant 2008

5-speed manual gearbox 0AF - Edition 08.2007

2.3.3	Torque settings
Component		Nm
Clutch pedal to mounting bracket		25
♦ Renew self-locking nuts
Crash bar to steering column mounting		10
bracket

2.4Removing and installing clutch pedal

Special tools and workshop equipment required ♦ Pliers -T10005-

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♦ Release tool -T10178-

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2.4.1

Removing

u

s

p

r

p

– Pushdriverseatascfarbackaspossibleandputsteeringwheel

l

a

in highest position.e

i

r

m

General

– Remove trim and cover below trim on drive side

m

o

body repairs, interior;oRep. Gr. 68 .

c

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– Now unbolt crash bar -1r- from in front of clutch pedal -2-.

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oitam

14 Rep. Gr.30 - Clutch

Jetta 2006 , Golf Variant 2008 5-speed manual gearbox 0AF - Edition 08.2007

o

V lksw

– Unboltclutchpedal-1- frommountingwagbrackete

-3- byremovingGdo

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nut -2- and pulling out bolt -5-.yV

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r

– Swing clutch pedal forwardt

slightly and remove over-centre

is

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h

bracket.

spring -4- from mountingsa

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– Release clutch pedal from master cylinder with pliers -

m

m

T10005- .

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– Remove clutch pedal.

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2.4.2Installing

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

Note

Renew self-locking nuts.

–Attach retainer -2- to master cylinder operating rod -1-.

–Press retainer into notch in clutch pedal until it can be heard to engage.

r m

2. Repairing clutch mechanism 15

Jetta 2006 , Golf Variant 2008

5-speed manual gearbox 0AF - Edition 08.2007

– Insertover-centrespringinmountingbracketfromabovewhile

holding end of spring with releaseotool -T10178- in installation

position.

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lksw

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en

en

A

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swag

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ot

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y

b

u

d

a

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– Insert tip of clutchs

pedal in bearing recess of over-centrea

spring.

i

n

r

t

o

e

th

e

u

o

r

a

a

s

c

s

clutch pedal slightly, push bolt through and tighten

c

– Depressle

e

n

p

t

self-lockingu

nut.

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–r Now bolt on crash bar -1- in front of clutch pedal -2-.

e

m

– mInstall trim and cover below trim on drive side General body

o

c

r

repairs, interior; Rep. Gr. 68 .

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2.4.3	Torque settings
Component		Nm
Clutch pedal to mounting bracket		25
♦ Renew self-locking nuts
Crash bar to steering column mounting		10
bracket

2.5Removing and installing mounting bracket

Special tools and workshop equipment required ♦ Hose clamps to 25 mm Ø -3094-

f i n

16 Rep. Gr.30 - Clutch

Jetta 2006 , Golf Variant 2008 5-speed manual gearbox 0AF - Edition 08.2007

Torque wrench -V.A.G 1331-

o

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5024 A-

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Spring-type clip pliers -VASn

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2.5.1

u

p

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a

Removingi

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r

a coded radio is fitted. If so, obtain anti-

e

– First check whetherm

theft code.

m

o

c

–

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e

t

With ignition switched off, disconnect battery Electrical sys

tem; Rep. Gr.

a

and connecting battery .

v

i

27 ; Disconnectingr

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–

r

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e

g

Remove complete air filter housing if it is near battery Rep.

n

Gr.

n

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C

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24 ; Repairing injection system .

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–

.

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i

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Remove battery and battery trayir Electrical system; Rep.

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Gr.

27 ; Removing and installingobatteryc

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Note

♦During the following work, ensure that no brake fluid lands on longitudinalmemberorgearbox.Ifthisdoeshappen,cleanthe affected areas thoroughly.

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

–Clamp off supply hose to master cylinder using hose clamp -3094- .

m

u

c

o

d

s

i

h

t

n

i

n

s s o f i n f o r

oitam

2. Repairing clutch mechanism 17

Jetta 2006 , Golf Variant 2008

5-speed manual gearbox 0AF - Edition 08.2007

–Loosen spring-type clip -3- with spring-type clip pliers -VAS 5024and pull supply hose off master cylinder.

–Releasesecuringclip-2-usingscrewdriverandpullpipe/hose line or plastic line -1- off master cylinder.

–Unclip clutch position sender -G476- from master cylinder -arrow- and remove with electrical connector attached -4-.

Note

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 .

–Now unbolt crash bar -1- from in front of clutch pedal -2-.

G.

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en

en

A

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,

–

e

hRemove securing nuts -1- and -2-.

l

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Ther uppersecuringnut-1-isaccessiblebetweentherelaycarrier

n

i

and the steering column trim.

o

t

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a

p

–i Remove mounting bracket -3-.

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2.5.2Installing

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

r e

18 Rep. Gr.30 - Clutch

Jetta 2006 , Golf Variant 2008 5-speed manual gearbox 0AF - Edition 08.2007

Note

♦Renew self-locking nuts.

♦Renew hose clips.

♦Allocate all components according to Electronic parts cata logue “ETKA” .

–Now bolt on crash bar -1- in front of clutch pedal -2-.

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

– Push pipe/hose line or plastic line -1- with seal -2- onto con

nection of master cylinder -4- until securing clip -3- engagesg

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audibly.

a

en

AG

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– Test line by tugging on it.

o

d

e

is

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th

– Bleed clutch system page 27 .

u

s

a

le

s

– Install battery Electrical system;d

n

Rep. Gr. 27 ; Removing

u

and installing battery .

i

e

t

m

t

e

r

filter housing

Rep. Gr. 24 ;

– If removed, install complete airt

Repairing injection system .

o

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2.5.3

a

Torque settings

i

c

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e

m

m

Component

o

Nm

o

c

r

Mounting bracket to body

v

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e

t

♦ Renew self-locking nuts

a

r

i

r

p

o

f

g

n

10

Crash bar to steering column mounting

o

i

y

bracket

p

.th

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2.6

o

Removing andinstalling masterdecylindertc

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b

et

or

Special tools and workshop equipment required

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2. Repairing clutch mechanism 19

Jetta 2006 , Golf Variant 2008

5-speed manual gearbox 0AF - Edition 08.2007

♦ Pliers -T10005-

2.6.1Removing

– Remove mounting bracket page 16 .

– Release retainer for master cylinder operating rod using pliers

-T10005- .

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pedal and stop and press

– Insert spacer -A- between clutcho

i

clutch pedal to spacer.

r

r

t

a

♦

p

1

/ " socket).

,

i

Length of spacer = about 40 mm (e.g.

n

2

s

e

– Release securing bar -B- and pull master cylinder out of

s

o

p

mounting bracket -arrow 1-pand -arrow 2-.

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2.6.2Installing

•Move clutch pedal to rest position at stop.

c t

20 Rep. Gr.30 - Clutch

Jetta 2006 , Golf Variant 2008 5-speed manual gearbox 0AF - Edition 08.2007

– Attach retainer -2- to master cylinder operating rod -1-.

–Insert spacer -A- between clutch pedal and stop and press clutch pedal to spacer.

♦ Length of spacer = about 40 mm (e.g. 1/2" socket).

–Engage master cylinder in mounting bracket -arrow 1- and -arrow 2-.

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in clutch pedal.

until retainer -2- engages audiblyth

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– Install mounting bracketle page 16 .

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2.7

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and installing clutch position

Removings

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2. Repairing clutch mechanism 21

Jetta 2006 , Golf Variant 2008

5-speed manual gearbox 0AF - Edition 08.2007

♦ Hose clamps -3094-

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Removing

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complete air filter housing if it is near battery Rep.

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Gr. 24 ; Repairing injection system .

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Electrical

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Remove battery, battery cover and battery tray

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Rep. Gr. 27 ; Removing and installing battery .

system;s

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pipe/hose line or plastic line -1- with a round component is

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installed directly beneath the master cylinder, the pipe/hose line

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or plastic line must be removed.

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♦ During ther following work, ensure that no brake fluid lands on

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under the master cylinder.

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–Clamp off supply hose to master cylinder using hose clamp -3094- .

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22 Rep. Gr.30 - Clutch

Jetta 2006 , Golf Variant 2008

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5-speed manual gearbox 0AF - Edition 08.2007

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– Release securingeclip -2- with a screwdriver and pull outarof

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master cylinderoto stop.

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line or plastic line -1- out from master cylinder

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– Pull pipe/hoses

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and sealuhose.

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All vehiclesm

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–

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electrical connector -4-.

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clutch position sender -G476- from master cylinder

– Unclipe,

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- and remove.

-arrowh

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2.7.2

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Installing

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order of removal. During this step, observe the

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following:

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♦

Renew hose clips.

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♦

Allocate all components according to Electronic parts cata

logue “ETKA” .

If the pipe/hose line or plastic line was removed:

–Push pipe/hose line or plastic line -1- with seal -2- onto con nection of master cylinder -4- until securing clip -3- engages audibly.

–Test line by tugging on it.

–Bleed clutch system page 27 .

All vehicles

–Install battery tray and battery Electrical system; Rep. Gr. 27 ; Removing and installing battery .

–If removed, install complete air filter housing Rep. Gr. 24 ; Repairing injection system .

–Reconnectbatteryandperformworkrequiredafterconnecting battery Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .

2. Repairing clutch mechanism 23

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5-speed manual gearbox 0AF - Edition 08.2007

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4 - Master cylinder

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and installing

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6 - Retainer

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To remove and install,i

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separate master cylinoc

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der from clutch pedal.

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page 14

7 - Clutch pedal

Removing and installingpage 14

8 - Self-locking hexagon nut,

25 Nm

Mounting bracket to body

Always renew 9 - O-ring

Pullontolineconnection

Insert with brake fluid

Seals, O-rings depending on configuration of line connections page 25

Allocation Electronic parts catalogue “ETKA”

10 - Seal

Pull onto line connection

Insert with brake fluid

Seals, O-rings depending on configuration of line connections page 25

Allocation Electronic parts catalogue “ETKA”

11 - Pipe/hose line

Allocation Electronic parts catalogue “ETKA”

To remove, remove battery and battery tray Electrical system; Rep. Gr. 27 ; Removing and installing battery .

12 - Retainer

For pipe/hose line Item 11 (page 24)

Secured to body.

13 - Plastic line

Allocation Electronic parts catalogue “ETKA”

To remove, remove battery and battery tray Electrical system; Rep. Gr. 27 ; Removing and installing battery .

24 Rep. Gr.30 - Clutch

Jetta 2006 , Golf Variant 2008 5-speed manual gearbox 0AF - Edition 08.2007

14 - Clip

Pull clip out to stop to remove or install line between master and slave cylinders

15 - Slave cylinder

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Removing and installing page 25

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16 - Dust cap

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17 - Bleeder valve

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18 - Gearbox

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19 - Hexagon bolt, 20 Nm

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20 - Retainer

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For pipe/hose lineh Item 11 (page 24)

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Item

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Version of line connection

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with shoulder -arrow 2-

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2.9Removing and installing slave cylinder

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

2. Repairing clutch mechanism 25

lksw o yV

db e is r o th u sa

nles

Jetta 2006 , Golf Variant 2008

5-speed manual gearbox 0AF - Edition 08.2007

2.9.1Removing

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

–With ignition switched off, disconnect battery Electrical sys tem; Rep. Gr. 27 ; Disconnecting and connecting battery .

–Remove complete air filter housing if it is near slave cylinderRep. Gr. 24 ; Repairing injection system .

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

–Pull gear selector cable from pin.

Metal relay lever

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

–Pull gate selector cable from pin.

–Pullsecuringclip-arrow3-offrelaylever-B-andremoverelay lever.

Plastic relay lever

–Remove relay lever together with cable end-piece from gear box page 50 .

Continuation for all

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

– Remove cable support bracket from gearbox -arrows-.

– Then tie up selector cable and gate cable.

– Place a lint-free cloth under slave cylinder.

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cylinders out of

– Pull clip -A- for line between master and slaveo

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slave cylinder to stop.

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– Pull line between master and slave cylinders out of support

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-C-.

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-B- out of slave

– Pull line between master and slave cylinderse

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,

cylinder and seal opening.

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–

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Unbolt slave cylinder -arrows- and

remove.

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Note

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26 Rep. Gr.30 - Clutch	b
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