Volkswagen Golf Variant 2010 User Manual

Service

Workshop Manual

Golf Variant 2007

Golf Variant 2010

Jetta 2005

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5-speed manual gearboxee0AF

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Edition 06.2010

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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 - rear differential

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Technical information shouldr

always be available to the foremen and mechanics, because their

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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

D3E801CBF24

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

Contents

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

1	Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1
1.1	Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1
1.2	Identification code, assembly allocation and 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 . . .													.	.	.		.	.		.	.		.	.	.	.	.	. . . .	. .	. .		.	.	.		.	.	.		.	.		. . .	.	.		.		.			.			. . . . . . . . . . . . . . . . . . .	10
	1											Fault finding, power transmission .																		.		.	. .	.		.	.	. .		.		.	. . .	. .	.		.		.			.			. . . . . . . . . . . . . . . . . . . . . . .	10
	2											Repairing clutch mechanism .																	. . . .	.		.	. .		.	.	.	.	.		.	.	. . .	. .		.		.	.			.			. . . . . . . . . . . . . . . . . . . . . . .	11
	2.1											Overview				.		. .		.	.		. .		.	. .	.	. . . .	. . . .	.	.	.	.	.	.		.	. .		.	.		. . .	. .	.		.		.			.			. . . . . . . . . . . . . . . . . . . . . . .	11
	2.2											Assembly overview - pedal cluster																		.	.	.	.	.	.	.	.	.		.	.	.	. . .	.	.	.		.			.	.			. . . . . . . . . . . . . . . . . . . . . . .	12
	2.3											Removing and installing over-centre spring																									.	.		.	.	.	. .	. .	.		.		.			.		.	. . . . . . . . . . . . . . . . . . . . . .	13
	2.4											Removing and installing clutch pedal																				.	.	.	.	.	.	.		.	.	.	. . .	.	.	.		.			.		.		. . . . . . . . . . . . . . . . . . . . . . .	18
	2.5											Removing and installing mounting bracket																								.	.	.		.	.		. . .	. .	.	.		.				.	.		. . . . . . . . . . . . . . . . . . . . . . .	24
	2.6											Removing and installingg															master cylinderG								.	.	.	.		.	.	.	. . .	.	.	.		.				.	.		. . . . . . . . . . . . . . . . . . . . . .	30
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												Removing and installing clutch position senderg																																.	.		.		.			.		.	. . . . . . . . . . . . . . . . . . . . . .
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	2.8													d																								a				t														35
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	2.10											s				and installing slave cylinder																																								38
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	3								te	d		Bleeding clutch system																																	a			l								41
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	4					r						Repairing clutch release mechanism																																				a								43
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	4.1											Assembly overview - clutch release mechanism																														.	. . .	. .		.		.			.		.		. . . . . . . . . . . . . . . . . . . . . .t	43
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	s											Removing and installing clutch release lever, release bearing and guide sleeve																																												44
	4.2
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34t- Controls, housing																					.	.	.		.	. .	.	. . .	. . .	.	. .		.		.	.	.	.		.		.	. .	. .	.			.		.			.		. .h. . . . . . . . . . . . . . . . .	48
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a	1											Repairing selector mechanism																																											c	48
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p	1.1											Repairing selector mechanism																																											o	48
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e	1.2											Removing and installing gear knob and cover																																											n	50
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p												Removing and installing gaiter with selector lever knob and noisefinsulation . . . . . . . . . .
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c1.4												. . . . . . . . . . . . . . . . . . . .Repairing gear lever and selector housing (through 10.06) . . . .f																																												52
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	1.5																																												.		.		.			.			. .r . . . . . . . . . . . . . . . . . . . .
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												Assembly overview - removing and installing selector cables .o																																												61
	1.6
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	o											Removing and installing selector mechanism																																								t		i		64
	1.7e																																					.		.		.	. . .	. .		.		.		.			n		. . . . . . . . . . . . . . . . . . . . . .
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					t							Adjusting selector mechanism																																					d		i					67
	1.8						i																						. . .	.	. .		.	.	.	.	.	.		.	.		. . .	. .	.		.			s .				.	. . . . . . . . . . . . . . . . . . . . . .
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										oPlastic relay lever														.	.	. . .		. . . .	. . . .	.	. .		.	.		. .	.	.		.		.	. . .	. .	m.		.		.			.			. . . . . . . . . . . . . . . . . . . . . . .
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												Removing and installing gearbox, Jetta 2005 , Golf Variant 2007 and Golf Variant
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												2010C.		.	.	.		.	.	.	.		.	. .		. . .		. . . .	. . . .	.	. .		.	.		. .	.	.		.				. .	.		.		.			.			. . . . . . . . . . . . . . . . . . . . . . .
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	2.1											Removingry				gearbox																						b				i														74
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	2.2											Installing gearboxbde												. .		. . .		. . . .	. . . .	.	.		.a.w.s			. .	.	.		.		.	. . .	. .	.		.		.			.			. . . . . . . . . . . . . . . . . . . . . . .	79
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												Removing and installing gearbox, Jetta 2011																													.	.	. . .	. .		.		.		.		.			. . . . . . . . . . . . . . . . . . . . . . .
	3.1											Removing gearbox, Jetta 2011 with 2.0 l - 85 kW engine																																			.		.			.			. . . . . . . . . . . . . . . . . . . . . . .	87
	3.2											Installing gearbox, Jetta 2011 with 2.0 l - 85 kW engine																																	.		.		.			.			. . . . . . . . . . . . . . . . . . . . . .	93
	4											Transporting gearbox														. .		. . . .	. . . .	.	. .		.	.	.	.	.	.		.	.	.	. . .	.	.	.		.		.		.			. . . . . . . . . . . . . . . . . . . . . . .	99
	5											Checking gear oil												. .		. . .		. . . .	. . . .	.	. .		.	.		. .	.	.		.		.	. . .	. .	.		.		.			.			. . . . . . . . . . . . . . . . . . . . . . .	100
	6											Dismantling and assembling gearbox .																					.		.	. .	.		.		.	.	. . .	.	.	.		.		.			.		. . . . . . . . . . . . . . . . . . . . . .	102
	6.1											Overview - gearbox .														. .	.	. . . .	. . .	.	. .		.	.	.	.	.	.		.	.		. . .	. .	.		.		.	.				.	. . . . . . . . . . . . . . . . . . . . . .	102
	6.2											Assembly overview .														. . .		. . . .	. . . .	.	. .		.	.		. .	.	.		.	.		. . .	. .	.	.		.		.			.		. . . . . . . . . . . . . . . . . . . . . . .	103

Contents i

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

6.3	Assembly overview - removing and installing cover for gearbox housing and 5th gear . . . .	104
6.4	Assembly overview - removing and installing clutch housing . . . . . . . . . . . . . . . . . . . . . . . .	105
6.5	Assembly overview - removing and installing input shaft, output shaft, differential, selector
	mechanism and selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	106
6.6	Dismantling and assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	107
7	Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	117
8	Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	122
9	Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	125

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

1	Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	130
1.1	Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	130
2	Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	141
2.1	Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	141

39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

1	Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . .	149
1.1	Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	149
1.2	Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	151

2Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

2.1	Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	153
2.2	Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	161

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ii Contents

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

00 – Technical data

1Gearbox identification

The 5-speed manual gearbox 0AF is installed in the Jetta 2005 , in the Golf Variant 2007 , in the Golf Variant 2010 and in the Jetta 2011 in conjunction with a 4-cylinder engine.

Allocation: page 1 .

1.1Location on gearbox

Code letters and production date -arrow 1-, manual gearbox 0AF -arrow 2-.

Manual gearbox 0AF -arrow 2-

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1. Gearbox identification 1

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

Manual gearbox			5-speed 0AF
Identification code		FVH	JHT	JHU
Allocation	Model	Jetta 2005	Jetta 2005	Jetta 2005
		Golf Variant 2007	Golf Variant 2007	Golf Variant 2007
				Golf Variant 2010
	Engine	1.6 l - 75 kW	1.6 l - 75 kW	1.4 l - 59 kW
Ratio	Final drive	68 : 15 = 4.533	68 : 15 = 4.533	68 : 15 = 4.533
Z1 : Z2
Capacity of manual gear		2.0 l	2.0 l	2.0 l
box
Drive shaft flange		100 mm	100 mm	90 mm

The following data can be found in the Electronic parts cata

logue “ETKA” :

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♦

Individual gear ratios

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Clutch allocation

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5-speed 0AF

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Golf Variant 2010

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Engine

i

1.6 l - 75 kW

,

s

1.4 le- 59 kW

Ratio

Final drive

s

68 : 15 = 4.533

o

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61 : 14r= 4.357

Z1 : Z2

u

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Capacity of manual gear

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2.0 l

i

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		90 mmc
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The following data can be found in the Electronic parts cata
logue “ETKA” :		n
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♦	Clutch allocation			P

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2.0 l - 85 kW

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59: 15 = 3.933

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2Rep. Gr.00 - Technical data

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Golf Variant 2007 , GolfoVariant 2010 , Jetta 2005 , Jetta 2011ee

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5-speed manual gearbox 0AF - Edition 06.2010

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Overview - power transmissionr m

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1 - Engine

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Gears

-Arrows- indicate direction of travel.

2. Overview - power transmission 3

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

I - 1st gear

II - 2nd gear

III - 3rd gear

IV - 4th gear

V - 5th gear

R - Reverse gear

A - Final drive

4Rep. Gr.00 - Technical data

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

3Calculating overall gear ratio “i”

Example:

	5th gear	Final drive
Drive gear	ZG1 = 37	ZA1 = 14
Driven gear	ZG2 = 50	ZG2 = 69

i = Z2 : Z1 1)

iG = Gear ratio = ZG2: ZG1= 37 : 50 = 0.740

iA = Final drive ratio = ZA2 : ZA1 = 69 : 14 = 4.929 Overall ratio = total ratio = iG x iA = 0.740 x 4.929 = 3.647

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 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

4General repair notes

To ensure flawless 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.

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.

♦When installing mounting brackets or waxed components, clean the contact surfaces. Contact surfaces must be free of wax and grease.

♦Allocate bolts and other components using Electronic parts catalogue “ETKA” .

♦Following installation, check gear oil level page 100 .

♦Capacity page 1

4.1.2

O-rings, seals, gaskets and sealants

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♦ Thoroughly clean housing joint surfaces before applyingiseal

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s

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ant .

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♦ Apply sealant -AMV 188 200 03uniformly but notletoo thick.

s

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♦ Renew O-rings, seals and gaskets.

itt

m

e

r

surface on

♦ When seals have been removed, check contactp

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e

rectify as nec

housings or shafts for burrs and damage andn

essary.

,

o

s

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l

o

♦ Before installing radial shaft seals, lightly oil outer diameter

h

w

and half-fill space between sealing lips -iarrow- with sealing

grease -G 052 128 A1- .

n

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r

o

r

a

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

p

n

i

,

♦ Press in new oil seals so that sealing lip does not contact the

s

e

shaft in the same place as the old seal (make use of insertion

s

o

depth tolerances).

p

p

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u

l

♦ Lightly oil O-rings before installing; this prevents the rings be

a

i

ing crushed when inserted.

c

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♦ After renewing seals and gaskets, check oilrlevel in gearbox

o

c

and replenish if necessary page 100 .

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6Rep. Gr.00 - Technical data

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

4.1.3Locking devices

♦ Do not overstretch retaining rings.

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

♦ Retaining rings must locate properly in grooves.

♦ Renew spring pins. Installation position: slit -A- should be in

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o♦ Loosen nuts or bolts in the order opposite to the tightening

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sequence.

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♦c Securing bolts and securing nuts which secure covers and

r

housings should be loosened and tightened diagonally in

e

m

m

stages if no tightening sequence is specified.

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Loosen and tighten bolts and nuts in stages in a diag

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♦ Always renewth self-locking bolts and nuts.

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♦ Threads of bolts secured with locking fluid must be cleaned with a wire brush. Then insert bolts with locking fluid - AMV 185 101 A1- .

♦ Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. with a thread chaser). Otherwise there is a danger of bolts shearing when subsequently being removed.

4.1.5Bearings

♦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.

e c

4. General repair notes 7

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

4.1.6Shims

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

♦Check for burrs and damage.

♦Install only flawless shims.

4.1.7Synchro-rings

♦Do not interchange. When reusing synchro-rings, always fit to the same synchromeshed gear.

♦Check for wear and renew if necessary.

♦Check grooves -arrow 1- of synchro-ring -A- and inner ring for flat spots (worn grooves).

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

♦If an intermediate ring -B- is installed, check the outer friction surface -arrow 2- and inner friction surface -arrow 3- of this intermediate ring for “scoring” and “signs of abnormal wear”.

♦Check the cone of the synchromeshed gear for “scoring” and “signs of abnormal wear”.

♦Moisten synchromesh mechanism with gear oil before instal ling.

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Gears, synchro-hubs, inner races for

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needle bearings

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♦ Heat inner races for needle bearingsn

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- before installing.

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inductive heater -VAS 6414e

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100 °C before installing.o

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heater -VAS 6414to approx. 100 °

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♦ Observe installation position.

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♦ After assembly, checkp

synchromeshed gears of 1st through

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5th gear for slight play, or for freedom of movement.

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4.1.10

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♦ When removing gearbox, remove slave cylinder without dis

connecting pipes.

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♦ If the clutch slave cylinder isoremoved with the hydraulic line

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will be pressed out of the slave cylinder.

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

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

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

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4. General repair notes

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

30 – Clutch

1Fault finding, power transmission

–Refer to Fault finding, power transmission; Rep. Gr. 30 ; Complaints about clutch and clutch mechanism and Fault finding, power transmission; Rep. Gr. 34 ; Complaints about selector mechanism .

.

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

2Repairing clutch mechanism

2.1Overview

Note

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

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

♦If reconnecting battery, follow procedure after connecting battery Electrical system; Rep.Gr. 27 ;Dis connecting and connecting battery .

♦Grease all bearing points and contact surfaces.Allocate grease according to Electronic parts catalogue “ETKA” .

I - Assembly overview - pedal cluster page 12

II - Assembly overview - hy draulics (LHD) page 35

III - Assembly overview - hy draulics (RHD) page 37

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2. Repairing clutch mechanism 11

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

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 13

Removing and installing

page 24

4 - Bolt

5 - Over-centre spring

Removing and installingpage 13

6 - Bearing bush

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7 - Pivot pin

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To remove and install,

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“2.4 Removing and installing clutch pedal”, page 18

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10 - Seal

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Between master cylinder and mounting bracket

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11r- Master cylinder

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a Removing and installing after removal of mounting bracket page 30i

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12 - Clutch position sender -G476-

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oRemoving and installing page 32

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Canbecheckedin“guidedfaultfinding”ofvehiclediagnosis,testing

andinformationsystem-VAS5051-.

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-F36- in “guided fault finding”.

The clutch position sender -G476- is identified as clutch pedal switcho

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13 - Clip

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14 - Supply hose

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15 - Hexagon nut, 25 Nm

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Self-locking

Qty. 3

12 Rep. Gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

For mounting bracket to bulkhead

Always renew

16 - Hexagon nut, 25 NmAlways renew

17 - Stop

For clutch pedal

Mounting bracket with damping -arrows-

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Removing and installing over-centree

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tools and workshop equipment required

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Release tool -T10178-

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2. Repairing clutch mechanism 13

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

2.3.1Removing

Perform the following steps:

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Notes

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location of the knee airbag is above the pedal

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

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theft code.

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With ignition switched off, disconnect battery Electrical sys

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tem; Rep. Gr. 27 ; Disconnecting and connecting battery .

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Continuation for all

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–

Push driver seat as far back as possible and move steering

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wheel to highest position.

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– Remove trim and cover below trim on drive side

General

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body repairs, interior; Rep. Gr.

68 .

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– rRemove bracket for knee airbag together with crash bar

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bodyrepairs,interior;Rep.Gr. 69;Airbag;Removing

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Generalt

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and installing knee airbag bracket.

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Continuation for all

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RemoveCcable guide -2- from steering column.

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–

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Remove footwellp

vent -3- Heating, air conditioning; Rep.

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Gr. 80 ; Repairingbdheatinge

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Vehicles without knee airbag

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

different ways. Crash bar may look different from as shown in

following illustrations.

Attachment with 2 bolts

– Remove crash bar -1- (2 bolts).

14 Rep. Gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

Attachment with 1 bolt

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

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

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–

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

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–

Pull off insulation.

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2. Repairing clutch mechanism 15

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

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

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– Unboltclutchpedal-1-froma

mountingbracket-3-byremoving

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-5-.

nut -2- and pulling out bolts

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Note

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hooked to operating rod of master cyl

The clutch pedal remainsis

inder.

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– Swing clutchr pedal down slightly and remove over-centre

n

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spring -4- from mounting bracket.

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2.3.2

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

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Renew self-locking nuts.

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16 Rep. Gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

–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 18 .

Some cars have damping -arrow- on the clutch pedal mounting

bracket.

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– Return thiseto installation position.

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Vehicles without knee airbag

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2. Repairing clutch mechanism 17

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

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

different ways.

Attachment with 2 bolts

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a

w

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– Install crash bar -1- and tighten 2 bolts tobspecified torque

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page 18 .

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Attachment with 1 bolt

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–

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tighten bolt -2- to specified torque

Install crash bar -1- ando

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page 18 .

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Continuation for all

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– Mount cable guide -2- on steering column.

r

p

r

o

f

–

Install footwell vent -3-

g

Heating, air conditioning; Rep. Gr.

i

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80 ; Repairing heating .

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h

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oc

y

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b

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–

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Install bracket for knee airbag together with crash bar Gen .

et

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

installing knee airbag bracket .

Continuation for all

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

–Ifdisconnected,connectbattery Electricalsystem;Rep.Gr. 27 ; Removing and installing battery .

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 (attachment with 2 bolts)
Crash bar to steering column mounting		20
bracket (attachment with 1 bolt)
♦ Renew bolts for crash bar

2.4Removing and installing clutch pedal

Special tools and workshop equipment required

r e s

o	d	s

18 Rep. Gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

♦ Pliers -T10005-

♦ Release tool -T10178-

Torque wrench -V.A.G 1331-

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2.4.1

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Removingi

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steps:

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t

a

p

Vehicles with knee airbag

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i

,

s

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s

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Note

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p

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u

l

a

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The installation location of the knee airbag is above the pedal

c

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cluster.

e

m

m

o

c

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

o

e

theft code.

t

p

v

i

r

r

– With ignition switched off, disconnect battery earth strap

e

g

f

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oC

Electricalsystem;Rep.Gr.o27;Disconnectingandconnecting

t

i

y

.

battery .

p

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Continuation for all

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kl

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b

d

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w

a

t

c

et

g

or

e

n

A

– Push driver seat as far back as possible and move steering

P

.G

wheel to highest position.

m

u

c

o

d

s

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h

t

			s
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n	i	n	o

2. Repairing clutch mechanism 19

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

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

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

enAG.

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a

w

s

– Remove cable guide -2- from steering column.

b

lk

o

V

d

y

e

is

– Remove footwell vent -3- Heating, air conditioning; Rep.

r

o

Gr. 80 ; Repairing heating .

s

th

u

a

s

le

Vehicles without knee airbag

d u

n

t

t

e

m

i

r

p

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t

o

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s

i

,

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l

o

h

w

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i

r

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t

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a

p

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

n

i

,

from as shown in

different ways. Crash bar may look differents

s

following illustrations.

e

p

o

r

Attachment with 2 bolts

u

a

p

l

– Remove crash bar -1- (2 bolts).

i

m

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e

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Attachment with 1 bolt

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d

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

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or

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Continuation for all

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20 Rep. Gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

– If fitted, remove damping -arrow- from lower area of clutch

pedal mounting bracket.

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enAG.V lkswagenA

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a

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is

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th

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d

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m

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s

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l

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o

t

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,

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l

a

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

r e

– Pull off insulation.

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

i n f

2. Repairing clutch mechanism 21

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

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

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

w

s

lk

o

V

y

–

Release clutch pedal from master cylinder with pliers - r

b

d

e

T10005- .

is

u

o

th

a

s

–

Remove clutch pedal.

s

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le

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d

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n

s

i

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2.4.2

Installing

i

s

,

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

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Note

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m

m

o

Renew self-locking nuts.

c

t

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o

e

a

v

i

r

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

p

r

f

g

n

– Pressretainerintonotchinclutchpedal-3-untilitcanbeheard

i

y

p

to engage.

o

th

C

.

g

i

r

y

p

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b

d

et

not

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							t
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22 Rep. Gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

– Insert over-centre spring -2- in mounting bracket from above

while holding end of spring with assembly tool -T10178- in in

o

stallation position.

G.

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agenA

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t

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s

i

,

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l

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t

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n

i

,

s

e

s

o

p

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u

p

l

a

i

c

• Receptacle -arrowr- for tip -A- of clutch pedal must stand ver

tically.

e

m

m

	o
	c
– Insert tip -A- of clutch pedal in bearing recess of over-centre
spring.	r
	o
	e
	t
	a
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	i
	r
	p
– Depress clutch pedal slightly, push bolt through and tighten
	r
	o
	f
self-locking nut to specified torque page 24 .
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	n
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	y
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					or	A	n
					P	.G

Some cars have damping -arrow- on the clutch pedal mounting bracket.

– Return this to installation position. Vehicles without knee airbag

o f i

2. Repairing clutch mechanism 23

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

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 2 bolts to specified torquepage 24 .

o

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ag

en

en

A

A

G

d

g

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s

a

i

n

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r

a

a

s

s

le

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n

1 bolt

Attachment withte

d

m

i

t

bar -1- and tighten bolt -2- to specified torque

– Install crashe

p

r

pageo

24 .

t

s

n

i

for all

Continuationl

,

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w

n

i

r

o

t

r

a

p

n

i

,

s

e

s

o

p

r

u

p

l

a

– Mount cable guide -2- on steering column.

i

c

r

e

–

m

Install footwell vent -3- Heating, air conditioning; Rep. Gr.

m

80 ; Repairing heating .

o

c

r

o

e

Vehicles withiknee airbag

t

a

v

r

–

p

Install bracketfgfor knee airbag together with crash bar Gen

r

o

C

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

n

i

y

bracket .

y

installing knee airbagC.

o

o

t

p

r

h

g

g

h

i

Continuation for all

i

oc

o

r

t

y

b

p

y

ybd

skl

V

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

–Ifdisconnected,connectbattery Electricalsystem;Rep.Gr. 27 ; Removing and installing battery .etc aw

e p t

i n f

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 (attachment with 2 bolts)
Crash bar to steering column mounting		20
bracket (attachment with 1 bolts)
♦ Renew bolts for crash bar

2.5Removing and installing mounting bracket

Special tools and workshop equipment required

24 Rep. Gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

♦ Hose clamps to 25 mm -3094-

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g

a

w

s

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is

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♦ Torque wrench -V.A.G 1331-

o

a

th

u

s

s

le

d

u

n

e

t

t

m

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t

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l

o

h

w

n

i

r

o

t

r

a

p

n

i

,

s

e

s

o

♦ Hose clip pliers -VAS 6362-u

p

r

p

l

a

i

c

r

e

m

m

o

c

r

o

e

t

a

v

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p

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n

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C

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d

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or

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uarant e

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A	n
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♦ Sealing tool -T10249-

t n e s

2.5.1Removing

Perform the following steps:

LHD

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

2. Repairing clutch mechanism 25

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 5-speed manual gearbox 0AF - Edition 06.2010

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

–Remove complete air filter housing if it is located close to the battery Rep. Gr. 24 ; Repairing injection system .

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

Continuation for all

Note

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

♦Lay a lint-free cloth under master cylinder.

–Clamp off supply hose to master cylinder with hose clamps up to 25 mm -3094- .

–Then seal supply hose with sealing tool -T10249/1- .

V

y

b

d

e

is

r

o

th

r

u

a

a

s

c

s

c

le

e

p

n

u

t

d

a

t

e

object

n

t

y

l

i

– Releasesecuringclip-2-usingscrewdriverorapointedi

a

r

m

b

i

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

l

i

t

o

t

p

y

w

i

– Unclip clutch position sender -G476- from mastern

cylinder

t

h

s

r

i

-4-.

,

e

-arrow- and remove with electrical connector attachede

s

l

p

o

h

e

w

c

t

n

t

Note

i

o

r

o

t

h

t

e

r

a

c

p

o

n

r

r

i

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

e

protect it from possible brake fluid spills.

,

s

c

e

t

s

n

o

e

p

s

r

General

s

u

o

p

f

– Remove trim and cover below trim on drive side

i

body repairs, interior; Rep. Gr. 68 .

l

a

n

i

f

c

o

r

e

r

Vehicles with knee airbag

m

m

a

m

t

i

o

i

n

o

c

n

r

t

o

e

Note

s

i

h

t

d

a

v

o

i

r

c

p

u

r

m

o

f

e

g

The installation location of the knee airbag is above the pedal

n

cluster.

n

i

t

y

.

C

p

o

o

C

p

y

.

t

r

h

i

g

g

h

i

t

r

y

b

p

o

c

y

y

V

o

kl

b

d

e

s

t

w

c

a

et

g

or

A

n

P

.G

26

Rep. Gr.30 - Clutch