VW Golf manuals

Volkswagen Golf Service & Repair Manual: Installing gearbox

Install in reverse order of removal, observing the following:
  Note
Renew bolts which are tightened by turning through a specified angle.
Renew self-locking nuts and bolts, and seals, O-rings and gaskets.
Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic Parts Catalogue.
Fit all cable ties in the original position when installing.
Recalibrate the immobiliser after installing a »new« gearbox.
   
–  In some cases, there are brackets on the front of the removed gearbox. Attach these brackets to the »new« gearbox.
 

Installing gearbox

In some vehicles, a cover is fitted over the engaging levers.
The cover prevents dirt getting in.
Specified torque: 8 Nm
Only Polo with petrol engine:
–  Remove right flange shaft.
 

Installing gearbox

–  Screw 2 bolts into flange and counterhold flange shaft with a lever in order to remove and install flange shaft.
–  Remove flange shaft with spring.
–  Close opening in drive shaft using a suitable plug.
All vehicles:
 

Installing gearbox

–  Renew needle bearing -arrow- in crankshaft → Rep. gr.13.
  Note
If the needle bearing in the crankshaft is damaged, the gears cannot be selected properly anymore because the clutch is supported on this bearing.
 

Installing gearbox

–  Fit gearbox onto gearbox support -3282- and secure it in place.
–  Clean input shaft splines and splines of torsional damper, remove corrosion and lubricate splines with only a very thin coating of grease → Electronic Parts Catalogue (ETKA). Remove excessive grease.
 

Installing gearbox

–  Make sure that the dowel sleeves -arrows B- for centring engine and gearbox are fitted in cylinder block and that the intermediate plate is fitted on the dowel sleeves. Insert any missing dowel sleeves.
–  For some engines, makes sure that the intermediate plate is attached to the sealing flange -arrow A-.
–  Carefully raise gearbox using engine and gearbox jack -V.A.G 1383 A- and move it to installation position with gearbox support -3282-.
–  Bolt gearbox to engine.
 

Installing gearbox

If the gearbox has been sealed so that no oil can escape, e.g. after a gearbox repair or after gearbox has been renewed:
–  Remove both plugs from breathers -arrows- and install breather caps (renew if necessary).
 

Installing gearbox

–  Bolt cable support bracket -1- to gearbox.
Install left assembly mounting as follows:
–  Always renew all bolts on left assembly mountings.
Golf, Golf Estate:
 

Installing gearbox

–  Bolt gearbox bracket -1- to gearbox.
 

Installing gearbox

–  The bracket can be moved within its seat with a screwdriver when bolts -2- are tightened → Rep. gr.10.
Polo:
 

Installing gearbox

–  Bolt gearbox bracket to gearbox.
 

Installing gearbox

–  Then, tighten vertical bolts -arrows-.
–  On Polo with diesel engine, install charge air cooler → Rep. gr.21.
All vehicles:
Continue installation in reverse order of removal.
–  If subframe has been removed, install it → Running gear, axles, steering; Rep. gr.40.
–  Install drive shafts → Running gear, axles, steering; Rep. gr.40.
–  Install front left wheel housing liner → General body repairs, exterior; Rep. gr.66.
 

Installing gearbox

–  If present, install heat shield above right drive shaft → Running gear, axles, steering; Rep. gr.40.
–  Install starter → Electrical system; Rep. gr.27.
–  Check selector lever cable adjustment and adjust it if necessary → Chapter.
  Note
Recalibrate the immobiliser after installing a »new« gearbox via vehicle diagnostic testerGuided functions.
Specified torques
Gearbox to engine → Chapter
Gearbox bracket to gearbox → Chapter
Wire retainer to gearbox cover → Chapter
Selector cable support bracket to gearbox → Chapter
Flange shaft to gearbox → Chapter
 

Installing gearbox

Removing gearbox
Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf SV 2015 ►, vehicles with petrol engine Brief description ...

Specified torques for gearbox
petrol engine, 1.4 l natural gas engine:   Item Bolt Nm 1, 5, 9 M12x70 80 2, 4 ...

Other materials:

Checking fuel system for leaks
Special tools and workshop equipment required Fuel system tester (so-called smoke tester) -KLI 9210- Adapter hose -KLI 9210/55-1-     Hose clamps up ...

Test after driving for 10 minutes
First read and observe the introductory information and safety warningsReconnect the tyre filler hose and check the tyre pressure on the tyre pressure display ⑥. 1.3 bar (19 psi / 130 kPa) and lower: Do not drive on! The tyre cannot be sealed adequately with the breakdown set. ...

Release tools for contacts
The various release tools serve as a means of detaching the different contacts from the contact housings without damage. A selection of release tools is included in wiring harness repair set -VAS 1978- and wiring harness repair set -VAS 1978A- ...

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