Volkswagen Golf Variant, Jetta. Manual - part 27

led on “new” gearbox in some cases 

⇒ page 114

 .

Note

There is no need to renew oil seal for flange shaft when doing

this.

– Remove right-hand flange shaft of gearbox in order to install

gearbox.

Gearbox with flange shafts, torque setting 

⇒ page 118

 .

Bolt has a 6 mm hexagon socket. Bolt can also be removed and

installed with socket -V.A.G 1669- .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

4. Removing and installing gearbox    

105

 

bearing from crankshaft and driving in .

– Check for proper seating of both dowel sleeves between en‐

gine and gearbox.

– Check for proper seating of intermediate plate.
– Guide selector lever cable as soon as possible into its cable

support bracket.

Check Bowden cable as soon as gearbox is raised. Be sure to

insert it in cable support bracket “early”.
Bowden cable must not be greased.
It must be possible to guide the engine and gearbox together by

hand until the engine flange and gearbox flange make contact all

around.
If not, “something has gone wrong”!
– Readjust gearbox support until engine and gearbox are

“aligned with each other”.

– Turn crankshaft slightly if necessary.

– After fitting starter motor, check that both breather caps are in

place -arrows-!

– Securing clip for selector lever Bowden cable -arrow- must be

renewed.

A securing clip which has been removed is not allowed to be in‐

stalled again. The clip will have lost its internal tension and so it

might fall off.
– Therefore, when installing, always use a “new” securing clip.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

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If the sheet metal has been bent downwards when the gearbox

was removed, it may cause noises. The cable will vibrate against

the sheet metal.
– Observe sheet metal. Press it back up in the tunnel during

installation.

– Always adjust selector lever cable 

⇒ page 43

 .

–

Carrying out basic adjustment

 

⇒ page 7

 .

Torque settings for gearbox installation 

⇒ page 107

 .

4.7

Torque settings “Gearbox to engine”

and notes on assembly mounting

The “next chapters” list the torque settings for gearbox installa‐

tion.
There is also information about the “left” assembly mounting.
Threaded connections that are not directly assigned to the gear‐

box can be found in the associated assembly groups.
For example: subframe and pendulum support.
The pendulum support on the subframe is part of the running

gear.
Consequently, further descriptions can also be found in ⇒  Run‐

ning gear, axles, steering; Rep. Gr.  40 .
Left assembly mounting
– Renew all bolts on left assembly mounting.
– First screw in all bolts by hand.

– First bolt bracket to gearbox -1- with 40 Nm + 90° further turn.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

4. Removing and installing gearbox    

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+ 90°.

Assembly overview - subframe, anti-roll bar, suspension links .
Gearbox to engine:
♦ 1.4 l/90 kW TFSI engine 

⇒ page 108

♦ 1.4 l/118 kW TSI engine 

⇒ page 108

♦ 1.6 l/75 kW MPI engine 

⇒ page 108

♦ 1.9 l/77 kW TDI PD engine 

⇒ page 109

♦ 1.6 l/77 kW TDI CR engine 

⇒ page 110

4.7.1

Engines: 1.4 l/90 kW TFSI, 1.4 l/118 kW TSI, 1.6 l/75 kW

M12 - 80 Nm

❑ If insert 18 mm -T10179-

is used: 65 Nm.

M10 - 40 Nm
- Arrows point towards dowel

sleeves

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