General Repair Notes; Components - Volkswagen Golf Variant 2007 Service Manual

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤
6-speed manual gearbox 02S - Edition 07.2009
4

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 dur‐
ing repair work.
A number of instructions generally applicable to the various repair
procedures - which were previously repeated a number of times
at various places in the workshop manual are summarised under
the topic "components"
manual.
4.1

Components

4.1.1 Gearbox
♦ When installing the manual gearbox, ensure that the dowel
sleeves between the engine and gearbox are correctly seated.
♦ 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" .
♦ Capacity ⇒ page 1 .
♦ If the gearbox is repaired, fill with gear oil.
Capacity, gearbox completely
dismantled
2.1 l
4.1.2 O-rings, seals, gaskets and sealants
♦ Thoroughly clean housing joint surfaces before applying seal‐
ant .
♦ Apply sealant -AMV 188 200 03- uniformly but not too thick.
♦ Always renew O-rings, seals and gaskets.
♦ After removing gaskets and seals, always inspect contact sur‐
face of housing or shaft for burrs resulting from removal or for
other signs of damage.
♦ Before installing radial shaft seals, lightly oil outer diameter
and half-fill space between sealing lips -arrow- with sealing
grease -G 052 128 A1- .
♦ The open side of the oil seal faces the side with fluid filling.
♦ Press in new oil seals so that sealing lip does not contact the
shaft in the same place as the old seal (make use of insertion
depth tolerances).
♦ Lightly oil O-rings before installing; this prevents the rings be‐
ing crushed when inserted.
♦ After renewing seals and gaskets, check oil level in gearbox
and replenish if necessary
8
Rep. Gr.00 - Technical data
⇒ page 8 . They apply to this workshop
Gearbox capacity, gearbox
partially dismantled
⇒ page 99
1.9 l
⇒ page 99 .