VW Golf manuals

Volkswagen Golf Service & Repair Manual: General 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 during repair work.
A number of generally applicable instructions for the various repair procedures which were previously repeated at numerous places in the workshop manual are summarised here. They apply to this workshop manual.
Guided fault finding, vehicle self-diagnosis and testing
Before performing repairs on the gearbox, determine the exact cause using vehicle diagnostic testerGuided fault finding, Vehicle self-diagnosis and Test instruments modes.
Gearbox
Do not run the engine or tow the vehicle with sump removed or when there is no gear oil in the gearbox.
Thoroughly clean all joints and surrounding areas before dismantling.
When installing, ensure that the dowel sleeves are fitted correctly.
Locking devices
Do not overstretch retaining rings.
Always renew retaining rings which have been damaged or overstretched.
Retaining rings must locate properly in grooves.
General notes
Gearbox The torque of the engine is transmitted via the flywheel to the dual clutch gearbox. The flywheel and the dual clutch are joined ...

Gaskets, seals
After removing gaskets and seals, always inspect contact surface of housing or shaft for burrs resulting from removal or for other signs of damage. ...

Other materials:

Digital sound package control unit -J525-, vehicles with Dynaudio
Special tools and workshop equipment required     Torque wrench -V.A.G 1783-   Protective cap for wiring harness connector -VAS 6223/9 ...

Safety precautions when working on the cooling system
Risk of scalding by hot coolant When the engine is warm, the cooling system is under pressure. Danger of scalding due to steam and hot coolant. –  Always wear safety gloves. –  Always wear safety goggles. –  ...

Removing and installing coolant pump for high-voltage battery -V590-
Special tools and workshop equipment required     Hose clamps, up to 25 mm -3094-   Hose clip pliers -VAS 6362- ...

© 2016-2019 Copyright www.vwgolf.org