Volkswagen Golf Plus 2009 User Manual

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Service

Workshop Manual

Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Passat 2006 ➤

5-speed manual gearbox 0A4

Edition 04.2010

Service Department. Technical Information

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List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups

Re pa ir G ro up

00 - Technical data

30 - Clutch

34 - Controls, housing

35 - Gears, shafts

39 - Final drive - differential

Service

Technical information should always be available to the foremen and mechanics, because their 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.

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

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

1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Identification codes, assembly allocation, capacities, Golf 2004 ▸ . . . . . . . . . . . . . . . . . . 2

1.3 Identification codes, assembly allocation, capacities, Golf 2009 ▸ . . . . . . . . . . . . . . . . . . 4

1.4 Identification codes, assembly allocation, capacities, Golf Plus 2005 ▸ . . . . . . . . . . . . . . 5

1.5 Identification codes, assembly allocation, capacities, Golf Plus 2009 ▸ . . . . . . . . . . . . . . 6

1.6 Identification codes, assembly allocation and capacities, Passat 2006 ▸ . . . . . . . . . . . . . . 6

2 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 Calculating overall gear ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.3 Removing and installing over-centre spring, Golf 2004 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.4 Removing and installing over-centre spring, Golf 2009 ▸ LHD . . . . . . . . . . . . . . . . . . . . . . 22

1.5 Removing and installing over-centre spring, Golf 2009 ▸ RHD . . . . . . . . . . . . . . . . . . . . . . 27

1.6 Removing and installing over-centre spring, Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Contents

5-speed manual gearbox 0A4 - Edition 04.2010

1.7 Removing and installing over-centre spring, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

1.8 Removing and installing clutch pedal, Golf 2004 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1.9 Removing and installing clutch pedal, Golf 2009 ▸ LHD . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1.10 Removing and installing clutch pedal, Golf 2009 ▸ RHD . . . . . . . . . . . . . . . . . . . . . . . . . . 49

1.11 Removing and installing clutch pedal, Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

1.12 Removing and installing clutch pedal, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

1.13 Removing and installing mounting bracket, Golf 2004 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . 61

1.14 Removing and installing mounting bracket, Golf 2009 ▸ LHD . . . . . . . . . . . . . . . . . . . . . . 67

1.15 Removing and installing mounting bracket, Golf 2009 ▸ right-hand drive and Golf Plus right-

hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

1.16 Removing and installing mounting bracket, Golf Plus left-hand drive . . . . . . . . . . . . . . . . 79

1.17 Removing and installing mounting bracket, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

1.18 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

1.19 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

1.20 Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

1.21 Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

2 Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

2.3 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

3 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

4 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

5 Repairing clutch, in conjunction with dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . 105

5.1 Identifying make of clutch, vehicles with 1.9 l - 66 kW turbo diesel engine and vehicles with

1.9 l - 77 kW turbo diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

5.2 Removing and installing Sachs clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

5.3 Repairing Sachs clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

5.4 Removing and installing LuK clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

5.5 Repairing LuK clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

6 Repairing clutch, in conjunction with one-piece flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Contents i

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

1 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

1.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

1.2 Overview of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

1.3 Removing and installing gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

1.4 Removing and installing gaiter with gear knob and noise insulation, Golf . . . . . . . . . . . . . . 118

1.5 Removing and installing gaiter with gear knob and noise insulation, Golf Plus . . . . . . . . . . 120

1.6 Removing and installing gaiter with selector lever knob and noise insulation, Passat . . . . 121

1.7 Repairing gear lever and selector housing (through 10.06) . . . . . . . . . . . . . . . . . . . . . . . . 123

1.8 Repairing gear lever and selector housing (from 11.06) . . . . . . . . . . . . . . . . . . . . . . . . . . 125

1.9 Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . . 131

1.10 Plastic relay lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

1.11 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

1.12 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

2 Removing and installing gearbox, Golf 2004 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

2.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

3 Removing and installing gearbox, Golf 2009 ▸ with turbo diesel engine . . . . . . . . . . . . . . 156

3.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

3.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

4 Removing and installing gearbox, Golf 2009 ▸ with petrol engine . . . . . . . . . . . . . . . . . . . . 171

4.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

4.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

5 Removing and installing gearbox, Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

5.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

5.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

6 Removing and installing gearbox, Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

6.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

6.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

7 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

8 Checking and topping up gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

8.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

8.2 Draining gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

8.3 Fill with gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

9 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

9.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

9.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

9.3 Removing and installing cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . . 225

9.4 Removing and installing gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . 226

9.5 Removing and installing input shaft, output shaft, differential and selector forks . . . . . . . . 227

9.6 Assembly sequence - removing and installing cover for gearbox housing and 5th gear . . 228

9.7 Assembly sequence - Dismantling and assembling gearbox completely . . . . . . . . . . . . . . 234

10 Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

11 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

12 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

1.2 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

2.1 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

2.2 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

ii Contents

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

3 Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

3.1 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

1 Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

1.2 Distinguishing seals for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

1.3 Renewing seal (two-part seal and sleeve for right flange shaft) . . . . . . . . . . . . . . . . . . . . . . 296

1.4 Renewing seal and sleeve together (one-piece seal and sleeve for right flange shaft) . . . . 299

2 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

3.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

3.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

Contents iii

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

iv Contents

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

00 – Technical data

1 Gearbox identification

5-speed manual gearbox 0A4 is installed in following vehicles:

Allocation, Golf 2004 ▸ ⇒ page 2

Allocation, Golf 2009 ▸ ⇒ page 4

Allocation, Golf Plus 2005 ▸ ⇒ page 5

Allocation, Golf Plus 2009 ▸ ⇒ page 6

Allocation, Passat 2006 ▸ ⇒ page 6

1.1 Location on gearbox

Codes and production date -arrow 1- manual gearbox 0A4

-arrow 2-

Manual gearbox 0A4 -arrow 2-

Codes and production date of gearbox

Example: FNE 10 11 3

Additional data provide information about the production facility.

Note

The gearbox code is also included on the vehicle data stickers.

I I I I I I I I

Identification

code

Day Month Year (2003)

of manufacture

1. Gearbox identification 1

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

1.2 Identification codes, assembly allocation, capacities, Golf 2004 ▸

Manual gearbox 5-speed 0A4 Identification code FNE GQQ HGR

Manufactured from

to

Allocation Engine 1.9 l - 77 kW

Ratio

Final drive 61 : 18 = 3.389 61 : 18 = 3.389 62 : 17 = 3.647

Z1 : Z2 Capacity of manual gearbox (gear‐

box completely dismantled) Capacity of manual gearbox

⇒ page 220 (gearbox partially dis‐

mantled) Drive shaft flange ∅ 100 mm 100 mm 100 mm

The following data can be found in the ⇒ Electronic parts cata‐ logue “ETKA” .

♦ Individual gear ratios

♦ Gear oil

♦ Clutch allocation

08.03

08.06

1.9 l - 77 kW

turbo diesel

1.9 l 1.9 l 1.9 l

1.7 l 1.7 l 1.7 l

03.05

08.06

2.5 l - 110 kW

Manual gearbox 5-speed 0A4 Identification code HDR GTB JCT

Manufactured from

to Allocation Engine 2.0 l - 85 kW 2.5 l - 110 kW 2.5 l - 110 kW Ratio

Z1 : Z2 Capacity of manual gearbox (gear‐

box completely dismantled) Capacity of manual gearbox

⇒ page 220 (gearbox partially dis‐

mantled) Drive shaft flange ∅ 100 mm 108 mm 108 mm

The following data can be found in the ⇒ Electronic parts cata‐ logue “ETKA” .

♦ Individual gear ratios

♦ Gear oil

♦ Clutch allocation

Manual gearbox 5-speed 0A4 Identification code JCR JCU JCV

Manufactured from

Allocation Engine 1.9 l - 66 kW

Final drive 62 : 17 = 3.647 62 : 17 = 3.647 62 : 17 = 3.647

to

01.05

08.06

1.9 l 1.9 l 1.9 l

1.7 l 1.7 l 1.7 l

05.06

06.08

turbo diesel

1.9 l - 77 kW turbo diesel

08.03

03.04

05.06

06.08

2.0 l - 85 kW 1.8 l - 110 kW

05.06

06.08

05.06

06.08

2 Rep. Gr.00 - Technical data

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

Manual gearbox 5-speed 0A4 Identification code JCR JCU JCV

Ratio

Final drive 61 : 18 = 3.389 72 : 17 = 4.235 63 : 16 = 3.938

Z1 : Z2 Capacity of manual gearbox (gear‐

1.9 l 1.9 l 1.9 l

box completely dismantled) Capacity of manual gearbox

1.7 l 1.7 l 1.7 l

⇒ page 220 (gearbox partially dis‐

mantled) Drive shaft flange ∅ 108 mm 100 mm 108 mm

The following data can be found in the ⇒ Electronic parts cata‐ logue “ETKA” .

♦ Individual gear ratios

♦ Gear oil

♦ Clutch allocation

Manual gearbox 5-speed 0A4 Identification code FNC HJK KCL

Manufactured from

Allocation Engine 1.9 l - 77 kW

Ratio Z1 : Z2

Capacity of manual gearbox (gear‐ box completely dismantled)

Capacity of manual gearbox

⇒ page 220 (gearbox partially dis‐

mantled) Drive shaft flange ∅ 100 mm 100 mm 100 mm

Final drive 61 : 18 = 3.778 63 : 16 = 3.938 61 : 18 = 3.778

The following data can be found in the ⇒ Electronic parts cata‐ logue “ETKA” .

♦ Individual gear ratios

to

♦ Gear oil

turbo diesel

05.06

12.06

1.9 l 1.9 l 1.9 l

1.7 l 1.7 l 1.7 l

05.06

12.06

1.8 l - 110 kW 1.9 l - 77 kW

12.06

06.08

turbo diesel

♦ Clutch allocation

Manual gearbox 5-speed 0A4 Identification code KBL KCD JQP

Manufactured from

to

Allocation Engine 1.9 l - 77 kW

07.07

06.08

05.07

12.07

07.07

06.08

2.5 l - 125 kW 1.8 l - 118 kW

turbo diesel

Ratio

Final drive 61 : 18 = 3.778 62 : 17 = 3.647 62 : 17 = 3.647

Z1 : Z2 Capacity of manual gearbox (gear‐

1.9 l 1.9 l 1.9 l box completely dismantled)

Capacity of manual gearbox

1.7 l 1.7 l 1.7 l

⇒ page 220 (gearbox partially dis‐

mantled) Drive shaft flange ∅ 100 mm 100 mm 100 mm

1. Gearbox identification 3

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

The following data can be found in the ⇒ Electronic parts cata‐ logue “ETKA” .

♦ Individual gear ratios

♦ Gear oil

♦ Clutch allocation

Manual gearbox 5-speed 0A4 Identification code KPF LHW

Manufac‐ tured

Allocation Engine 2.5 l - 125 kW 1.9 l - 77 kW

Ratio

Final drive 61 : 18 = 3.778 62 : 17 = 3.647

Z1 : Z2 Capacity of manual gear‐

box (gearbox completely dismantled)

Capacity of manual gear‐ box ⇒ page 220 (gearbox partially dismantled)

Drive shaft flange ∅ 100 mm 100 mm

The following data can be found in the ⇒ Electronic parts cata‐ logue “ETKA” .

♦ Individual gear ratios

♦ Gear oil

♦ Clutch allocation

1.3 Identification codes, assembly allocation, capacities, Golf 2009 ▸

Manual gearbox 5-speed 0A4 Identification code KQM LLL LHW

Manufac‐ tured

Allocation Engine 1.9 l - 81 kW

from

to

from

to

07.07

06.08

1.9 l 1.9 l

1.7 l 1.7 l

06.08

05.09

04.08

06.08

turbo diesel

08.08 05.09

2.0 l - 81 kW

turbo diesel

1.6 l - 66 kW turbo diesel

1.6 l - 77 kW turbo diesel

Ratio

Final drive 61 : 18 = 3.778 61 : 18 = 3.778 62 : 17 = 3.647

Z1 : Z2 Capacity of manual gear‐

1.9 l 1.9 l 1.9 l box (gearbox completely dismantled)

Capacity of manual gear‐

1.7 l 1.7 l 1.7 l box ⇒ page 220 (gearbox partially dismantled)

Drive shaft flange ∅ 100 mm 100 mm 100 mm

The following data can be found in the ⇒ Electronic parts cata‐ logue “ETKA” .

♦ Individual gear ratios

♦ Gear oil

4 Rep. Gr.00 - Technical data

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

♦ Clutch allocation

Manual gearbox 5-speed 0A4 Identification code LUB KCD KPF

Manufac‐ tured

Allocation Engine 1.9 l - 77 kW

from

to

05.09 08.09

09.09

2.5 l - 125 kW 2.5 l - 125 kW

08.09

05.10

turbo diesel

Ratio

Final drive 62 : 17 = 3.647 62 : 17 = 3.647 61 : 18 = 3.778

Z1 : Z2 Capacity of manual gear‐

1.9 l 1.9 l 1.9 l box (gearbox completely dismantled)

Capacity of manual gear‐

1.7 l 1.7 l 1.7 l box ⇒ page 220 (gearbox partially dismantled)

Drive shaft flange ∅ 100 mm 100 mm 100 mm

The following data can be found in the ⇒ Electronic parts cata‐ logue “ETKA” .

♦ Individual gear ratios

♦ Gear oil

♦ Clutch allocation

Manual gearbox 5-speed 0A4 Identification code MDZ LEA

Manufac‐ tured

Allocation Engine 1.9 l - 77 kW

Ratio Z1 : Z2

Capacity of manual gear‐ box (gearbox completely dismantled)

Capacity of manual gear‐ box ⇒ page 220 (gearbox partially dismantled)

Drive shaft flange ∅ 100 mm 100 mm

The following data can be found in the ⇒ Electronic parts cata‐ logue “ETKA” .

♦ Individual gear ratios

♦ Gear oil

from

to

Final drive 61 : 18 = 3.778 61 : 18 = 3.778

11.09 05.10

turbo diesel

1.9 l 1.9 l

1.7 l 1.7 l

08.10

2.5 l - 125 kW

♦ Clutch allocation

1.4 Identification codes, assembly allocation, capacities, Golf Plus 2005 ▸

Manual gearbox 5-speed 0A4 Identification code HNV JCX KBL

Manufactured from

to

11.04

05.06

01.09

11.07

01.09

1. Gearbox identification 5

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

Manual gearbox 5-speed 0A4 Identification code HNV JCX KBL

Allocation Engine 1.9 l - 66 kW

turbo diesel

1.9 l - 77 kW turbo diesel

Ratio

Final drive 62 : 17 = 3.647 62 : 17 = 3.647 61 : 18 = 3.778

1.9 l - 66 kW turbo diesel

1.9 l - 77 kW turbo diesel

Z1 : Z2 Capacity of manual gearbox 1.9 l 1.9 l 1.9 l Capacity of manual gearbox

1.7 l 1.7 l 1.7 l

⇒ page 220 (gearbox partially dis‐

mantled) Drive shaft flange ∅ 100 mm 100 mm 100 mm

The following data can be found in the ⇒ Electronic parts cata‐ logue “ETKA” .

♦ Individual gear ratios

♦ Gear oil

♦ Clutch allocation

1.5 Identification codes, assembly allocation, capacities, Golf Plus 2009 ▸

Manual gearbox 5-speed 0A4 Identification code KQM LHW LUB

Manufactured from

Allocation Engine 2.0 l - 81 kW

Ratio Z1 : Z2

Capacity of manual gearbox 1.9 l 1.9 l 1.9 l

Final drive 61 : 18 = 3.778 62 : 17 = 3.647 62 : 17 = 3.647

Capacity of manual gearbox

⇒ page 220 (gearbox partially dis‐

mantled) Drive shaft flange ∅ 100 mm 100 mm 100 mm

to

The following data can be found in the ⇒ Electronic parts cata‐

turbo diesel

logue “ETKA” .

01.09 02.09 05.09

1.7 l 1.7 l 1.7 l

1.6 l - 66 kW turbo diesel

1.6 l - 77 kW turbo diesel

1.9 l - 77 kW turbo diesel

♦ Individual gear ratios

♦ Gear oil

♦ Clutch allocation

1.6 Identification codes, assembly allocation and capacities, Passat 2006 ▸

Manual gearbox 5-speed 0A4 Identification code HNV JCX JQP

Manufac‐ tured

from

to

01.05

05.06

11.08

05.07

11.08

6 Rep. Gr.00 - Technical data

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

Manual gearbox 5-speed 0A4 Identification code HNV JCX JQP

Allocation Engine 1.9 l - 77 kW

turbo diesel

1.9 l - 66 kW turbo diesel

1.8 l - 118 kW

1.9 l - 77 kW turbo diesel

Ratio

Final drive 62 : 17 = 3.647 62 : 17 = 3.647 62 : 17 = 3.647

Z1 : Z2 Capacity of manual gear‐

1.9 l 1.9 l 1.9 l box (gearbox completely dismantled)

Capacity of manual gear‐

1.7 l 1.7 l 1.7 l box ⇒ page 220 (gear‐ box partially dismantled)

Drive shaft flange ∅ 100 mm 100 mm 107 mm

The following data can be found in the ⇒ Electronic parts cata‐ logue “ETKA” .

♦ Individual gear ratios

♦ Gear oil

♦ Clutch allocation

Manual gearbox 5-speed 0A4 Identification code JVF KBM KJF

Manufac‐ tured

Allocation Engine 2.0 l - 85 kW 1.9 l - 77 kW

Ratio Z1 : Z2

Capacity of manual gearbox (gearbox com‐ pletely dismantled)

Capacity of manual gearbox ⇒ page 220 (gearbox partially dis‐ mantled)

Drive shaft flange ∅ 100 mm 100 mm 100 mm

The following data can be found in the ⇒ Electronic parts cata‐ logue “ETKA” .

♦ Individual gear ratios

♦ Gear oil

♦ Clutch allocation

Final drive

Manual gearbox 5-speed 0A4

from

to

Identification code KBL LHP MDM

Manufac‐ tured

from

to

03.07

11.08

72 : 17 = 4.235 62 : 17 = 3.647 62 : 17 = 3.647

1.9 l 1.9 l 1.9 l

1.7 l 1.7 l 1.7 l

01.08 11.08

Allocation Engine 1.9 l - 77 kW

turbo diesel

05.07

11.08

turbo diesel

12.07

2.0 l - 85 kW turbo diesel

08.09

2.0 l - 81 kW turbo diesel

1.6 l - 77 kW turbo diesel

2.0 l - 81 kW turbo diesel

1.6 l - 77 kW turbo diesel

1. Gearbox identification 7

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

Manual gearbox 5-speed 0A4 Identification code KBL LHP MDM

Ratio Z1 : Z2

Capacity of manual gearbox (gearbox com‐ pletely dismantled)

Capacity of manual gearbox ⇒ page 220 (gearbox partially dis‐ mantled)

Drive shaft flange ∅ 100 mm 100 mm 100 mm

The following data can be found in the ⇒ Electronic parts cata‐ logue “ETKA” .

♦ Individual gear ratios

♦ Gear oil

♦ Clutch allocation

Final drive

61 : 18 = 3.778 62 : 17 = 3.647 62 : 17 = 3.647

1.9 l 1.9 l 1.9 l

1.7 l 1.7 l 1.7 l

8 Rep. Gr.00 - Technical data

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

2 Overview - power transmission

Designation

-Arrows- indicate direction of travel.

1 - Engine

2 - Clutch

3 - Manual gearbox

4 - Input shaft

5 - Output shaft

6 - Differential

Gears

-Arrows- indicate direction of travel.

2. Overview - power transmission 9

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

I - 1st gear

II - 2nd gear

III - 3rd gear

IV - 4th gear

V - 5th gear

R - Reverse gear

A - Final drive

10 Rep. Gr.00 - Technical data

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

3 Calculating overall gear ratio “i”

Example:

5th gear Final drive

Drive gear ZG1 = 39 ZA1 = 18

Driven gear ZG2 = 29 ZA2 = 61

i = Z2 : Z1

iG = Gear ratio = ZG2 : ZG1= 29 : 39 = 0.744

iA = Final drive ratio = ZA2 : ZA1 = 61 : 18= 3.389

Overall ratio = total ratio = iG x iA = 0.744 x 3.389 = 2.521

1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear

1)

3. Calculating overall gear ratio “i” 11

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

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” ⇒ page 12 . They apply to this workshop 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” .

♦ If the gearbox is repaired, fill with gear oil.

Capacity, gearbox completely

dismantled

Capacity, gearbox partially dis‐

mantled ⇒ page 220

1.9 l 1.7 l

4.1.2 Seals and sealing rings

♦ Before installing oil seal, half-fill space between sealing lips

with sealing grease -G 052 128 A1- -arrow-.

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

♦ After installing, check oil level ⇒ page 220 .

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

ing crushed when inserted.

♦ Thoroughly clean parting surfaces and apply sealant -AMV

188 200 03- .

♦ Apply sealant uniformly but not too thick.

4.1.3 Sealant

♦ Thoroughly clean housing joint surfaces before applying seal‐

ing paste.

♦ Evenly apply a thin coat of sealing paste -AMV 188 200 03- .

♦ Breather holes must remain free of sealing paste.

12 Rep. Gr.00 - Technical data

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

4.1.4 Locking devices

♦ Renew retaining rings.

♦ Do not overstretch retaining rings.

♦ Retaining rings must locate properly in grooves.

♦ Renew spring pins. Installation position: slot must be in line

with direction of force.

4.1.5 Nuts and bolts

♦ Loosen and tighten securing bolts and nuts for covers and

housings diagonally.

♦ Do not cant especially delicate parts, such as clutch pressure

plates. Loosen and tighten bolts and nuts in stages in a diag‐ onal sequence.

♦ Torque settings are specified for unoiled bolts and nuts.

♦ Always renew self-locking bolts and nuts.

♦ Ensure with threaded connections that contact surfaces as

well as nuts and bolts are rewaxed only after assembly, if nec‐ essary.

♦ Use a thread chaser to clear residual locking fluid from all

threaded holes into which self-locking bolts are to be screwed. Otherwise there is a danger of bolts shearing when subse‐ quently being removed.

4.1.6 Bearings

♦ Install new tapered roller bearings as supplied and do not lu‐

bricate additionally.

♦ Install needle bearings with lettered side (thicker metal) to‐

wards fitting tool.

♦ Tapered roller bearings fitted to one shaft must be renewed as

a set. Use same make of bearings.

♦ Heat inner races to about 100 °C with the inductive heater -

VAS 6414- before installing.

♦ Do not interchange outer or inner races of bearings of the

same size. The bearings are matched in pairs.

4.1.7 Shims

♦ 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. General repair notes 13

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

4.1.8 Synchro-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”, “signs of abnormal wear” and “blue discolouration (due to overheating)”.

♦ Check cone of synchromeshed gear for “scoring” and “signs

of abnormal wear”.

♦ Moisten synchromesh mechanism with gear oil before instal‐

ling.

4.1.9 Gear wheels

♦ Before installing, clean and heat with the inductive heater -

VAS 6414- to maximum 100° C.

4.1.10 Synchromeshed gears

♦ After assembly, check synchromeshed gears for slight play, or

for freedom of movement.

4.1.11 Clutch

♦ Ensure that the pressure plate does not cant: loosen and tight‐

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.

14 Rep. Gr.00 - Technical data

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

30 – Clutch

1 Repairing clutch mechanism

1.1 Overview

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 .

♦

When reconnecting battery, refer to ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .

♦

Grease all bearing points and contact surfaces.

♦

Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

I - Assembly overview - pedal cluster ⇒ page 16

II - Assembly overview - hy‐ draulics (LHD) ⇒ page 94

III - Assembly overview - hy‐ draulics (RHD) ⇒ page 96

1. Repairing clutch mechanism 15

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

1.2 Assembly overview - pedal cluster

1 - Bulkhead

❑ With support for mount‐

ing bracket

2 - Seal

❑ Always renew ❑ Between mounting

❑ Self-adhesive ❑ Bond to mounting

3 - Mounting bracket

❑ For mounting clutch

❑ Is provided with damp‐

❑ Removing and instal‐

bracket and bulkhead

bracket

pedal

ing in some equipment variants ⇒ page 17

ling, Golf 2004 ▸

⇒ page 61

ling, Golf 2009 ▸ LHD

⇒ page 67

ling, Golf 2009 ▸ righthand drive, and Golf Plus right-hand drive

⇒ page 73

❑ Removing and instal‐

ling, Golf Plus left-hand drive ⇒ page 79

❑ Removing and instal‐

ling, Passat

⇒ page 84

4 - Bolt

5 - Over-centre spring

❑ Removing and installing, Golf 2004 ▸ ⇒ page 18 ❑ Removing and installing, Golf 2009 ▸ LHD ⇒ page 22 ❑ Removing and installing, Golf 2009 ▸ RHD ⇒ page 27 ❑ Removing and installing, Golf Plus ⇒ page 32 ❑ Removing and installing, Passat ⇒ page 37

6 - Bearing bush

7 - Pivot pin

8 - Clutch pedal

❑ Removing and installing, Golf 2004 ▸ ⇒ page 38 ❑ Removing and installing, Golf 2009 ▸ LHD ⇒ page 44 ❑ Removing and installing, Golf 2009 ▸ RHD ⇒ page 49 ❑ Removing and installing, Golf Plus ⇒ page 54 ❑ Removing and installing, Passat ⇒ page 59

9 - Retainer

❑ To remove and install, separate master cylinder from clutch pedal (⇒ Removing and installing clutch

pedal)

16 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

❑ Golf 2004 ▸ ⇒ page 38 ❑ Golf 2009 ▸ LHD ⇒ page 44 ❑ Golf 2009 ▸ RHD ⇒ page 49 ❑ Golf Plus ⇒ page 54 . ❑ Passat ⇒ page 59

10 - Seal

❑ Always renew ❑ Between master cylinder and mounting bracket

11 - Master cylinder

❑ Removing and installing after removal of mounting bracket ⇒ page 88

12 - Clutch position sender -G476-

❑ Removing and installing ⇒ page 90 ❑ Can be checked in “guided fault finding” of vehicle diagnosis, testing and information system -VAS 5051- . ❑ The clutch position sender -G476- is identified as clutch pedal switch -F36- in “guided fault finding”.

13 - Clip

❑ Pull out clip to stop to remove and install pipe/hose line

14 - Supply hose

❑ Rubber ❑ From 12. 05, plastic ⇒ page 95 ❑ Golf 2009 ▸ and Golf Plus 2009 ▸ plastic ⇒ page 95

15 - Self-locking hexagon nut, 25 Nm

❑ Qty. 3 ❑ For mounting bracket to bulkhead ❑ Always renew

16 - Hexagon nut, 25 Nm

❑ Always renew

17 - Stop

❑ For clutch pedal

Mounting bracket with damping -arrows-

1. Repairing clutch mechanism 17

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

1.3 Removing and installing over-centre spring, Golf 2004 ▸

Special tools and workshop equipment required

♦ Release tool -T10178-

♦ Torque wrench -V.A.G 1331-

1.3.1 Removing

– Push driver seat as far back as possible and put steering wheel

in highest position.

– Remove trim and cover below trim on drive side ⇒ General

body repairs, interior; Rep. Gr. 68 .

– Remove cable guide -2- from steering column.

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

Gr. 80 ; Repairing heating

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

Attachment with 2 bolts

18 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Remove crash bar -1- (2 bolts).

Attachment with 1 bolt

– Remove crash bar -1- (1 bolt -2-).

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

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

– Pull off damping.

1. Repairing clutch mechanism 19

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Push damping upwards in area of upper securing nut -1-

above clutch pedal -A- in -direction of arrow-.

– Unbolt clutch pedal -1- from mounting bracket -3- by removing

nut -2- and pulling out bolt -5-.

Note

The clutch pedal remains hooked to operating rod of master cyl‐ inder.

– Swing clutch pedal down slightly and remove over-centre

spring -4- from mounting bracket.

1.3.2 Installing

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

Note

Renew self-locking nuts.

20 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– 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 22 .

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

– Return it to installation position.

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

Attachment with 2 bolts

1. Repairing clutch mechanism 21

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Install crash bar -1- and tighten the 2 bolts to specified torque

⇒ page 22 .

Attachment with 1 bolt

– Install crash bar -1- and tighten bolt -2- to specified torque

⇒ page 22 .

– Install trim and cover below trim on drive side ⇒ General body

repairs, interior; Rep. Gr. 68 .

1.3.3 Torque settings

Component Nm

Clutch pedal to mounting bracket ♦ Renew self-locking nuts.

Crash bar to steering column mounting bracket (attachment with 2 bolts)

Crash bar to steering column mounting bracket (attachment with 1 bolt)

♦ Renew bolts for crash bar

1.4 Removing and installing over-centre

Special tools and workshop equipment required

♦ Release tool -T10178-

spring, Golf 2009 ▸ LHD

25

10

20

22 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

♦ Torque wrench -V.A.G 1331-

1.4.1 Removing

Vehicles with knee airbag

Note

The installation location of the knee airbag is above the pedal cluster.

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

theft code.

– With ignition switched off, disconnect battery ⇒ Electrical sys‐

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

Continuation for all

– Push driver seat as far back as possible and put steering wheel

in highest position.

– 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 ⇒

Interior equipment; Rep. Gr. 69 ; Airbag; Removing and in‐ stalling knee airbag bracket (Golf 2009 ▸) .

Continuation for all

– Remove cable guide -2- from steering column.

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

Gr. 80 ; Repairing heating

Vehicles without knee airbag

1. Repairing clutch mechanism 23

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.

Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Remove crash bar -1- (bolt -2-).

Continuation for all

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

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

– Pull off damping.

24 Rep. Gr.30 - Clutch

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.

Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Push damping upwards in area of upper securing nut -1-

above clutch pedal -A- in -direction of arrow-.

– Unbolt clutch pedal -1- from mounting bracket -3- by removing

nut -2- and pulling out bolt -5-.

Note

The clutch pedal remains hooked to operating rod of master cyl‐ inder.

– Swing clutch pedal down slightly and remove over-centre

spring -4- from mounting bracket.

1.4.2 Installing

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

Note

Renew self-locking nuts.

1. Repairing clutch mechanism 25

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.

Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– 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 -1- in bearing recess of over-centre

spring.

– Depress clutch pedal slightly, push bolt through and tighten

self-locking nut to specified torque ⇒ page 27 .

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

– Return it to installation position.

Vehicles without knee airbag

26 Rep. Gr.30 - Clutch

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.

Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Install crash bar -1- and tighten bolt -2- to specified torque

⇒ page 27 .

Continuation for all

– Mount cable guide -2- on steering column.

– Install foot well vent -3-.⇒ Rep. Gr. 80

Vehicles with knee airbag

– Install bracket for knee airbag together with crash bar ⇒ Inte‐

rior equipment; Rep. Gr. 69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ▸) .

Continuation for all

– Install trim and cover below trim on drive side ⇒ General body

repairs, interior; Rep. Gr. 68 .

– If disconnected, connect battery ⇒ Electrical system; Rep. Gr.

27 ; Removing and installing battery .

1.4.3 Torque settings

Component Nm

Clutch pedal to mounting bracket ♦ Renew self-locking nuts.

Crash bar to steering column mounting bracket

♦ Renew bolt for crash bar

1.5 Removing and installing over-centre

Special tools and workshop equipment required

♦ Pliers -T10005-

spring, Golf 2009 ▸ RHD

25

20

1. Repairing clutch mechanism 27

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

♦ Release tool -T10178-

♦ Torque wrench -V.A.G 1331-

1.5.1 Removing

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

theft code.

– With ignition switched off, disconnect battery ⇒ Electrical sys‐

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

– Push driver seat as far back as possible and put steering wheel

in highest position.

– Remove trim and cover below trim on driver side ⇒ Body Re‐

pairs; Rep. Gr. 68 .

– Remove bracket for knee airbag ⇒ Interior equipment; Rep.

Gr. 69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ▸) .

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

Gr. 80 ; Repairing heating

28 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Remove cable guide -2- from steering column.

– Remove crash bar -1- (bolt -2-).

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

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

– Pull off damping.

1. Repairing clutch mechanism 29

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Push damping upwards in area of upper securing nut -1-

above clutch pedal -A- in -direction of arrow-.

– Unbolt clutch pedal -1- from mounting bracket -3- by removing

nut -2- and pulling out bolt -5-.

Note

The clutch pedal remains hooked to operating rod of master cyl‐ inder.

– Swing clutch pedal down slightly and remove over-centre

spring -4- from mounting bracket.

1.5.2 Installing

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

Note

Renew self-locking nuts.

30 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

– 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 -1- in bearing recess of over-centre

spring.

– Depress clutch pedal slightly, push bolt through and tighten

self-locking nut to specified torque ⇒ page 32 .

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

– Return it to installation position.

5-speed manual gearbox 0A4 - Edition 04.2010

1. Repairing clutch mechanism 31

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Install crash bar -1- and tighten bolt -2- to specified torque

⇒ page 32 .

– Mount cable guide -2- on steering column.

– Install foot well vent -3-.⇒ Rep. Gr. 80

– Install bracket for knee airbag ⇒ Interior equipment; Rep. Gr.

69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ▸) .

– Install trim and cover below trim on drive side ⇒ General body

repairs, interior; Rep. Gr. 68 .

– If disconnected, connect battery ⇒ Electrical system; Rep. Gr.

27 ; Removing and installing battery .

1.5.3 Torque settings

Component Nm

Clutch pedal to mounting bracket ♦ Renew self-locking nuts

Crash bar to steering column mounting bracket

♦ Renew bolt for crash bar

25

20

1.6 Removing and installing over-centre spring, Golf Plus

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

1.6.1 Removing

– Push driver seat as far back as possible and put steering wheel

in highest position.

32 Rep. Gr.30 - Clutch

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.

Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Remove trim and cover below trim on drive side ⇒ General

body repairs, interior; Rep. Gr. 68 .

– Carefully cut through cable tie -1-.

– Remove cable guide -2- from steering column.

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

Gr. 80 ; Repairing heating

– Now remove crash bar -A- from in front of clutch pedal by re‐

moving bolt -B-.

– Remove footwell trim by removing nuts -arrows-.

– Remove bolt -1- and pull universal joint -2- from steering box.

1. Repairing clutch mechanism 33

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.

Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

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

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

– Pull off damping.

– Push damping upwards in area of upper securing nut -1-

above clutch pedal -A- in -direction of arrow-.

34 Rep. Gr.30 - Clutch

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.

Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Unbolt clutch pedal -1- from mounting bracket -3- by removing

nut -2- and pulling out bolt -5-.

Note

The clutch pedal remains hooked to operating rod of master cyl‐ inder.

– Swing clutch pedal down slightly and remove over-centre

spring -4- from mounting bracket.

Note

spring.

1.6.2 Installing

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

Renew self-locking nuts.

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

– Receptacle -arrow- for tip -A- of clutch pedal must be vertical.

– Insert tip of clutch pedal in bearing recess of over-centre

– Depress clutch pedal slightly, push bolt through and tighten

self-locking nut to specified torque ⇒ page 36 .

1. Repairing clutch mechanism 35

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

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

– Return it to installation position.

– Install crash bar -A-, tightening bolt -B- ⇒ page 36 .

– Fit universal joint -2- to steering box and screw in new bolt

-1- ⇒ Running gear, axles, steering; Rep. Gr. 48 ; Assembly overview - Steering .

– Carry out basic setting for steering angle sender -G85- with

vehicle diagnosis, testing and information system -VAS 5051- .

– Install trim and cover below trim on drive side ⇒ General body

repairs, interior; Rep. Gr. 68 .

1.6.3 Torque settings

Component Nm

Clutch pedal to mounting bracket

25

♦ Renew self-locking nuts

Crash bar to steering column mounting

Bolt M6 = 5

bracket

36 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

Component Nm

Crash bar to steering column mounting

Bolt M8 = 20

bracket ♦ Renew bolts for crash bar

1.7 Removing and installing over-centre spring, Passat

Special tools and workshop equipment required

♦ Release tool -T10178-

1.7.1 Removing

– Remove mounting bracket ⇒ page 84 .

– Carefully clamp lower section of clutch pedal in vice having

protective jaw pads.

– Separate clutch pedal from master cylinder ⇒ page 59 .

– Press over-centre spring from clutch pedal -arrow 1- while

swinging mounting bracket in -direction of arrow 2-.

– Carefully release tension from over-centre spring.

– Swing mounting bracket back to starting position and remove

over-centre spring.

1.7.2 Installing

• Clutch pedal is separated from master cylinder.

– Carefully clamp lower section of clutch pedal in vice having

protective jaw pads.

– Insert over-centre spring in mounting bracket.

1. Repairing clutch mechanism 37

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐

tically.

– Apply release tool -T10178- to middle of over-centre spring

and swing up mounting bracket.

– Compress over-centre spring -arrow 1-.

– At the same time, move mounting bracket downwards

-arrow 2- until over-centre spring can be pressed onto locating lug -A- of clutch pedal.

WARNING

If over-centre spring is improperly installed, it will jump uncon‐ trolled out of mounting bracket.

Place a cloth over over-centre spring.

Check operation of over-centre spring.

Do this by moving mounting bracket up and down a few times.

– Connect clutch pedal to master cylinder ⇒ page 59 .

– Install mounting bracket, Passat ⇒ page 84 .

1.8 Removing and installing clutch pedal,

Special tools and workshop equipment required

♦ Pliers -T10005-

Golf 2004 ▸

38 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

♦ Release tool -T10178-

♦ Torque wrench -V.A.G 1331-

5-speed manual gearbox 0A4 - Edition 04.2010

1.8.1 Removing

– Push driver seat as far back as possible and put steering wheel

in highest position.

– Remove trim and cover below trim on drive side ⇒ General

body repairs, interior; Rep. Gr. 68 .

– Remove cable guide -2- from steering column.

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

Gr. 80 ; Repairing heating

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

Attachment with 2 bolts

– Remove crash bar -1- (2 bolts).

Attachment with 1 bolt

1. Repairing clutch mechanism 39

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Remove crash bar -1- (1 bolt -2-).

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

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

– Pull off damping.

40 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Push damping upwards in area of upper securing nut -1-

above clutch pedal -A- in -direction of arrow-.

– Unbolt clutch pedal -1- from mounting bracket -3- by removing

nut -2- and pulling out bolt -5-.

– Swing clutch pedal forward slightly and remove over-centre

spring -4- from mounting bracket.

– Release clutch pedal from master cylinder with pliers -

T10005- .

– Remove clutch pedal.

1.8.2 Installing

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

Note

Renew self-locking nuts.

1. Repairing clutch mechanism 41

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

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

– Press retainer into notch in clutch pedal -3- until it can be heard

to engage.

– 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 -1- must be ver‐

tical.

– Insert tip -A- 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 43 .

42 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

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

– Return it to installation position.

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 the 2 bolts to specified torque

⇒ page 43 .

Attachment with 1 bolt

5-speed manual gearbox 0A4 - Edition 04.2010

– Install crash bar -1- and tighten bolt -2- to specified torque

⇒ page 43 .

– Install trim and cover below trim on drive side ⇒ General body

repairs, interior; Rep. Gr. 68 .

1.8.3 Torque settings

Component Nm

Clutch pedal to mounting bracket ♦ Renew self-locking nuts.

Crash bar to steering column mounting bracket (attachment with 2 bolts)

Crash bar to steering column mounting bracket (attachment with 1 bolts)

♦ Renew bolts for crash bar

25

10

20

1. Repairing clutch mechanism 43

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

1.9 Removing and installing clutch pedal, Golf 2009 ▸ LHD

Special tools and workshop equipment required

♦ Pliers -T10005-

♦ Release tool -T10178-

♦ Torque wrench -V.A.G 1331-

1.9.1 Removing

Vehicles with knee airbag

Note

The installation location of the knee airbag is above the pedal cluster.

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

theft code.

– With ignition switched off, disconnect battery ⇒ Electrical sys‐

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

44 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

Continuation for all

– Push driver seat as far back as possible and put steering wheel

in highest position.

– 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 ⇒

Interior equipment; Rep. Gr. 69 ; Airbag; Removing and in‐ stalling knee airbag bracket (Golf 2009 ▸) .

Continuation for all

– Remove cable guide -2- from steering column.

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

Gr. 80 ; Repairing heating

Vehicles without knee airbag

– Remove crash bar -1- (bolt -2-).

Continuation for all

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

1. Repairing clutch mechanism 45

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

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

– Pull off damping.

– Push damping upwards in area of upper securing nut -1-

above clutch pedal -A- in -direction of arrow-.

– Unbolt clutch pedal -1- from mounting bracket -3- by removing

nut -2- and pulling out bolt -5-.

– Swing clutch pedal forward slightly and remove over-centre

spring -4- from mounting bracket.

46 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Release clutch pedal from master cylinder with pliers -

T10005- .

– Remove clutch pedal.

1.9.2 Installing

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

Note

Renew self-locking nuts.

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

– Press retainer into notch in clutch pedal -3- until it can be heard

to engage.

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

while holding end of spring with assembly tool -T10178- in in‐ stallation position.

1. Repairing clutch mechanism 47

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Receptacle -arrow- for tip -A- of clutch pedal -1- must be ver‐

tical.

– Insert tip -A- 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 49 .

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

– Return it to installation position.

Vehicles without knee airbag

– Install crash bar -1- and tighten bolt -2- to specified torque

⇒ page 49 .

Continuation for all

– Mount cable guide -2- on steering column.

– Install foot well vent -3-.⇒ Rep. Gr. 80

Vehicles with knee airbag

– Install bracket for knee airbag together with crash bar ⇒ Inte‐

rior equipment; Rep. Gr. 69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ▸) .

Continuation for all

– Install trim and cover below trim on drive side ⇒ General body

repairs, interior; Rep. Gr. 68 .

– If disconnected, connect battery ⇒ Electrical system; Rep. Gr.

27 ; Removing and installing battery .

48 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

1.9.3 Torque settings

Component Nm

Clutch pedal to mounting bracket ♦ Renew self-locking nuts

25

Crash bar to steering column mounting

20

bracket ♦ Renew bolt for crash bar

1.10 Removing and installing clutch pedal, Golf 2009 ▸ RHD

Special tools and workshop equipment required

♦ Pliers -T10005-

♦ Release tool -T10178-

Torque wrench -V.A.G 1331-

1.10.1 Removing

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

theft code.

1. Repairing clutch mechanism 49

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– With ignition switched off, disconnect battery ⇒ Electrical sys‐

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

– Push driver seat as far back as possible and put steering wheel

in highest position.

– Remove trim and cover below trim on drive side ⇒ General

body repairs, interior; Rep. Gr. 68 .

– Remove bracket for knee airbag ⇒ Interior equipment; Rep.

Gr. 69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ▸) .

– Remove cable guide -2- from steering column.

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

Gr. 80 ; Repairing heating

– Remove crash bar -1- (bolt -2-).

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

50 Rep. Gr.30 - Clutch

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.

Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

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

– Pull off damping.

– Push damping upwards in area of upper securing nut -1-

above clutch pedal -A- in -direction of arrow-.

– Unbolt clutch pedal -1- from mounting bracket -3- by removing

nut -2- and pulling out bolt -5-.

– Swing clutch pedal forward slightly and remove over-centre

spring -4- from mounting bracket.

1. Repairing clutch mechanism 51

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Release clutch pedal from master cylinder with pliers -

T10005- .

– Remove clutch pedal.

1.10.2 Installing

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

Note

Renew self-locking nuts.

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

– Press retainer into notch in clutch pedal until it can be heard

to engage.

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

while holding end of spring with assembly tool -T10178- in in‐ stallation position.

52 Rep. Gr.30 - Clutch

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.

Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐

tically.

– Insert tip of clutch pedal -1- in bearing recess of over-centre

spring.

– Depress clutch pedal slightly, push bolt through and tighten

self-locking nut to specified torque ⇒ page 54 .

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

– Return it to installation position.

– Install crash bar -1- and tighten bolt -2- to specified torque

⇒ page 54 .

– Mount cable guide -2- on steering column.

– Install foot well vent -3-.⇒ Rep. Gr. 80

– Install bracket for knee airbag ⇒ Interior equipment; Rep. Gr.

69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ▸) .

– Install trim and cover below trim on drive side ⇒ General body

repairs, interior; Rep. Gr. 68 .

1. Repairing clutch mechanism 53

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

1.10.3 Torque settings

Component Nm

Clutch pedal to mounting bracket ♦ Renew self-locking nuts

25

Crash bar to steering column mounting

20

bracket ♦ Renew bolt for crash bar

1.11 Removing and installing clutch pedal, Golf Plus

Special tools and workshop equipment required

♦ Pliers -T10005-

♦ Torque wrench -V.A.G 1331-

1.11.1 Removing

– Push driver seat as far back as possible and put steering wheel

in highest position.

– Remove trim and cover below trim on drive side ⇒ General

body repairs, interior; Rep. Gr. 68 .

– Remove cable guide -2- from steering column.

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

Gr. 80 ; Repairing heating

54 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

– Now remove crash bar -A- from in front of clutch pedal by re‐

moving bolt -B-.

– Remove footwell trim by removing nuts -arrows-.

5-speed manual gearbox 0A4 - Edition 04.2010

– Remove bolt -1- and pull universal joint -2- from steering box.

1. Repairing clutch mechanism 55

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

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

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

– Pull off damping.

– Push damping upwards in area of upper securing nut -1-

above clutch pedal -A- in -direction of arrow-.

56 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Unbolt clutch pedal -1- from mounting bracket -3- by removing

nut -2- and pulling out bolt -5-.

– Swing clutch pedal forward slightly and remove over-centre

spring -4- from mounting bracket.

– Release clutch pedal from master cylinder with pliers -

T10005- .

– Remove clutch pedal.

Note

1.11.2 Installing

Renew self-locking nuts.

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

– Press retainer into notch in clutch pedal until it can be heard

to engage.

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

1. Repairing clutch mechanism 57

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Receptacle -arrow- for tip -A- of clutch pedal must be vertical.

– 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 59 .

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

– Return it to installation position.

– Install crash bar -A-, tightening bolt -B- to specified torque

⇒ page 59 .

58 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

– Fit universal joint -2- to steering box and screw in new bolt

-1- ⇒ Running gear, axles, steering; Rep. Gr. 48 ; Assembly overview - Steering .

– Carry out basic setting for steering angle sender -G85- with

vehicle diagnosis, testing and information system -VAS 5051- .

– Install trim and cover below trim on drive side ⇒ General body

repairs, interior; Rep. Gr. 68 .

1.11.3 Torque settings

Component Nm

Clutch pedal to mounting bracket ♦ Renew self-locking nuts

Crash bar to steering column mounting bracket

♦ Renew bolts for crash bar

5-speed manual gearbox 0A4 - Edition 04.2010

25

Bolt M6 = 5

Bolt M8 = 20

1.12 Removing and installing clutch pedal, Passat

Special tools and workshop equipment required

♦ Pliers -T10005-

♦ Release tool -T10178-

1. Repairing clutch mechanism 59

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

♦ Torque wrench -V.A.G 1331-

1.12.1 Removing

– Remove mounting bracket ⇒ page 84 .

– Carefully clamp mounting bracket in vice having protective jaw

pads.

– Unbolt clutch pedal -1- from mounting bracket -3- by removing

nut -2- and pulling out bolt -5-.

– Swing clutch pedal forward slightly and remove over-centre

spring -4- from mounting bracket.

– Release clutch pedal from master cylinder with pliers -

T10005- .

– Remove clutch pedal.

1.12.2 Installing

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

Note

Renew self-locking nuts.

60 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

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

– Press retainer into notch in clutch pedal -3- until it can be heard

to engage.

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

while holding end of spring with assembly tool -T10178- in in‐ stallation position.

– Insert tip of clutch pedal -1- in bearing recess of over-centre

spring.

– Depress clutch pedal slightly, push bolt through and tighten

self-locking nut.

– Install mounting bracket ⇒ page 84 .

1.12.3 Torque setting

Component Nm

Clutch pedal to mounting bracket ♦ Renew self-locking nuts

1.13 Removing and installing mounting bracket, Golf 2004 ▸

Special tools and workshop equipment required

♦ Hose clamps to 25 mm -3094-

25

1. Repairing clutch mechanism 61

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

♦ Torque wrench -V.A.G 1331-

♦ Spring-type clip pliers -VAS 5024 A-

♦ Sealing tool -T10249-

1.13.1 Removing

LHD

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

theft code.

– With ignition switched off, disconnect battery ⇒ Electrical sys‐

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

– Remove complete air filter housing if it is near battery ⇒ Rep.

Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing injection system .

– Remove battery and battery tray ⇒ Electrical system; Rep.

Gr. 27 ; Battery; Removing and installing battery .

62 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

Continuation for all

Note

♦

During the following work, ensure that no brake fluid lands on longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.

♦

Place a lint-free cloth under the master cylinder.

– Clamp off supply hose to master cylinder using hose clamp

-3094- .

– If necessary, loosen spring-type clip -3- with assembly tool -

VAS 5024- and pull supply hose off master cylinder.

– In addition, for disconnecting, you can close it with the sealing

tool -T10249/1- (⇒ figure above).

– Release securing clip -2- using screwdriver or a pointed object

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

– Unclip clutch position sender -G476- from master cylinder

-arrow- and remove with electrical connector attached -4-.

Note

When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.

– Remove trim and cover below trim on drive side ⇒ General

body repairs, interior; Rep. Gr. 68 .

– Remove cable guide -2- from steering column.

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

Gr. 80 ; Repairing heating

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

Attachment with 2 bolts

– Unbolt crash bar (2 bolts).

Attachment with 1 bolt

1. Repairing clutch mechanism 63

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Remove crash bar -1- (1 bolt -2-).

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

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

– Pull off damping.

64 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Push damping upwards in area of upper securing nut -1-

above clutch pedal -A- in -direction of arrow-.

– Remove securing nuts -1- and -2-.

The upper securing nut -1- is accessible between the relay carrier and the steering column trim.

– Remove mounting bracket -3-.

1.13.2 Installing

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

1. Repairing clutch mechanism 65

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

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

Note

♦

Renew self-locking nuts.

♦

Renew hose clips.

♦

Allocate all components according to ⇒ Electronic parts cata‐ logue “ETKA” .

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 the 2 bolts to specified torque

⇒ page 67 .

Attachment with 1 bolt

– Install crash bar -1- and tighten bolt -2- to specified torque

⇒ page 67 .

– Install trim and cover below trim on drive side ⇒ General body

repairs, interior; Rep. Gr. 68 .

66 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Push pipe/hose line -1- with seal -2- onto connection of master

cylinder -4- until securing clip -3- engages audibly.

– Test pipe/hose line by tugging on it.

– After removing hose clamp -3094- , return supply hose to its

original position, if necessary.

– Bleed clutch system ⇒ page 101 .

LHD

– Install battery ⇒ Electrical system; Rep. Gr. 27 ; Removing

and installing battery .

– Remove complete air filter housing if it is near battery ⇒ Rep.

Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing injection system .

1.13.3 Torque settings

Component Nm

Mounting bracket to bulkhead ♦ Renew self-locking nuts.

Crash bar to steering column mounting bracket (attachment with 2 bolts)

Crash bar to steering column mounting bracket (attachment with 1 bolt)

♦ Renew bolts for crash bar

1.14 Removing and installing mounting bracket, Golf 2009 ▸ LHD

Special tools and workshop equipment required

♦ Hose clamps to 25 mm -3094-

25

10

20

1. Repairing clutch mechanism 67

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

♦ Torque wrench -V.A.G 1331-

♦ Sealing tool -T10249-

1.14.1 Removing

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

theft code.

– With ignition switched off, disconnect battery ⇒ Electrical sys‐

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

– Remove complete air filter housing if it is near battery ⇒ Rep.

Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing injection system .

– Remove battery and battery tray ⇒ Electrical system; Rep.

Gr. 27 ; Removing and installing battery .

Note

♦

During the following work, ensure that no brake fluid lands on longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.

♦

Place a lint-free cloth under the master cylinder.

– Clamp off supply hose to master cylinder using hose clamp

-3094- .

– Pull supply hose -1- off master cylinder.

68 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– In addition, for disconnecting, you can close it with the sealing

tool -T10249/1- (⇒ figure above).

– Release securing clip -2- using screwdriver or a pointed object

and pull pipe/hose line or plastic line -3- off master cylinder.

– Unclip clutch position sender -G476- from master cylinder

-arrow- and remove with electrical connector attached -4-.

Note

When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.

– Remove trim and cover below trim on drive side ⇒ General

body repairs, interior; Rep. Gr. 68 .

Vehicles with knee airbag

Note

The installation location of the knee airbag is above the pedal cluster.

– Remove bracket for knee airbag together with crash bar ⇒

– Remove cable guide -2- from steering column.

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

Vehicles without knee airbag

– Remove crash bar -1- (bolt -2-).

Continuation for all

Interior equipment; Rep. Gr. 69 ; Airbag; Removing and in‐ stalling knee airbag bracket (Golf 2009 ▸) .

Gr. 80 ; Repairing heating

1. Repairing clutch mechanism 69

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

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

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

– Pull off damping.

– Push damping upwards in area of upper securing nut -1-

above clutch pedal -A- in -direction of arrow-.

70 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Remove securing nuts -1- and -2-.

The upper securing nut -1- is accessible between the relay carrier and the steering column trim.

– Remove mounting bracket -3-.

1.14.2 Installing

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

Note

Renew self-locking nuts.

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

Vehicles without knee airbag

– Install crash bar -1- and tighten bolt -2- to specified torque

⇒ page 72 .

Continuation for all

1. Repairing clutch mechanism 71

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Mount cable guide -2- on steering column.

– Install footwell vent -3-. ⇒ Heating, Air conditioning; Rep. Gr.

80 ; Repairing heating; Removing and installing left footwell vent

Vehicles with knee airbag

– Install bracket for knee airbag together with crash bar ⇒ Inte‐

rior equipment; Rep. Gr. 69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ▸) .

Continuation for all

– Install trim and cover below trim on drive side ⇒ General body

repairs, interior; Rep. Gr. 68 .

– Push pipe/hose line or plastic line -1- with seal -2- onto con‐

nection of master cylinder -4- until securing clip -3- engages audibly.

– Test line by tugging on it.

– After removing hose clamp -3094- , return supply hose to its

original position, if necessary.

– Bleed clutch system ⇒ page 101 .

– Install battery ⇒ Electrical system; Rep. Gr. 27 ; Removing

and installing battery .

– If removed, install complete air filter housing ⇒ Rep. Gr. 23 ;

Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing injection system

1.14.3 Torque settings

Component Nm

Mounting bracket to bulkhead ♦ Renew self-locking nuts.

Crash bar to steering column mounting bracket

♦ Renew bolt for crash bar

25

20

72 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

1.15 Removing and installing mounting bracket, Golf 2009 ▸ right-hand drive and Golf Plus right-hand drive

Special tools and workshop equipment required

♦ Hose clamps to 25 mm -3094-

♦ Sealing tool -T10249-

♦ Hook -3438-

♦ Torque wrench -V.A.G 1331-

1.15.1 Removing

Vehicles with knee airbag

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

theft code.

– With ignition switched off, disconnect battery ⇒ Electrical sys‐

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

Vehicles with turbo diesel engine and particle filter

– Remove shielding -A- from particle filter ⇒ Rep. Gr. 26 ; Parts

of exhaust system; Assembly overview - front exhaust pipe with particle filter .

Continuation for all

A heat shield is installed in conjunction with some engines. Ap‐ pearance may be different from that illustrated.

1. Repairing clutch mechanism 73

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Remove heat shield from pipe/hose line -arrows-.

Note

♦

During the following work, ensure that no brake fluid lands on longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.

♦

Place a lint-free cloth under the master cylinder.

– Clamp off supply hose to master cylinder using hose clamp

-3094- .

– Pull supply hose 3 off master cylinder.

– In addition, for disconnecting, you can seal supply hose with

sealing tool -T10249/1- .

Release securing clip -1- with a screwdriver or pointed object

– Pull pipe/hose line -2- off master cylinder.

– Unclip clutch position sender -G476- from master cylinder

-arrow- and remove with electrical connector attached -3-.

Note

When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.

– Remove trim and cover below trim on drive side ⇒ General

body repairs, interior; Rep. Gr. 68 .

Golf

– Remove bracket for knee airbag ⇒ Interior equipment; Rep.

Gr. 69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ▸) .

The installation location of the knee airbag is above the pedal cluster.

Continuation for all

Note

74 Rep. Gr.30 - Clutch

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.

Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Remove cable guide -2- from steering column by cutting cable

tie -1- if necessary.

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

Gr. 80 ; Repairing heating

– Remove crash bar -1- (bolt -2-).

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

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

– Pull off damping.

1. Repairing clutch mechanism 75

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Push damping upwards in area of upper securing nut -1-

above clutch pedal -A- in -direction of arrow-.

– Remove securing nuts -1- and -2-.

The upper securing nut -1- is accessible between the relay carrier and the steering column trim.

– Remove mounting bracket -3-.

1.15.2 Installing

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

Note

Renew self-locking nuts.

76 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

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

– Install crash bar -1- and tighten bolt -2- to specified torque

⇒ page 78 .

5-speed manual gearbox 0A4 - Edition 04.2010

– Fit cable guide -2- onto steering column, secure with cable tie

-1- if necessary.

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

80 ; Repairing heating

Golf

– Install bracket for knee airbag ⇒ Interior equipment; Rep. Gr.

69 ; Airbag; Removing and installing knee airbag bracket (Golf 2009 ▸) .

Continuation for all

– Install trim and cover below trim on drive side ⇒ General body

repairs, interior; Rep. Gr. 68 .

– Press pipe/hose line -2- with seal into connection of master

cylinder.

1. Repairing clutch mechanism 77

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Clip in securing clip -1-.

– Test line by tugging on it.

– Clip clutch position sender -G476- into master cylinder with

electrical connector -3- attached -arrow-.

Hook -3438- can be used for installing pipe/hose line -2- and clutch position sender -3-.

– After removing hose clamp -3094- , return supply hose to its

original position, if necessary.

– If present, fold heat shield around the pipe/hose line

-arrows-.

Vehicles with particle filter

– Install shielding -A- onto particle filter ⇒ Rep. Gr. 26 ; Parts

of exhaust system; Assembly overview - front exhaust pipe with particle filter .

Continuation for all

– Bleed clutch system ⇒ page 101 .

– If disconnected, connect battery ⇒ Electrical system; Rep. Gr.

27 ; Removing and installing battery .

1.15.3 Torque settings

Component Nm

Mounting bracket to bulkhead

25

♦ Renew self-locking nuts

Crash bar to steering column mounting

20

bracket ♦ Renew bolt for crash bar

78 Rep. Gr.30 - Clutch

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.

Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

1.16 Removing and installing mounting bracket, Golf Plus left-hand drive

Special tools and workshop equipment required

♦ Hose clamps -3094-

♦ Torque wrench -V.A.G 1331-

♦ Spring-type clip pliers -VAS 5024 A-

♦ Hose clamp -3094-

Sealing tool -T10249-

1.16.1 Removing

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

theft code.

– With ignition switched off, disconnect battery ⇒ Electrical sys‐

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

– Remove complete air filter housing if it is near battery ⇒ Rep.

Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing injection system .

1. Repairing clutch mechanism 79

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Remove battery, battery cover and battery tray ⇒ Electrical

system; Rep. Gr. 27 ; Removing and installing battery .

Note

♦

During the following work, ensure that no brake fluid lands on longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.

♦

Place a lint-free cloth under the master cylinder.

– Clamp off supply hose to master cylinder using hose clamp

-3094- .

– If necessary, loosen spring clip -3- using assembly tool -VAS

5024- .

– In addition, for disconnecting, you can close it with the sealing

tool -T10249/1- (⇒ figure above).

– Pull off supply hose.

– Pull clip -2- for pipe/hose line out of master cylinder to stop.

– Pull pipe/hose line -1- out from master cylinder and seal hose.

– Unclip clutch position sender -G476- from master cylinder

-arrow- and remove with electrical connector attached -4-.

Note

When performing work in the footwell, put cloths on the carpet to protect it from possible brake fluid spills.

– Push driver seat as far back as possible and put steering wheel

in highest position.

– Remove driver side compartment and cover ⇒ General body

repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim panels .

– Carefully cut through cable tie -1-.

– Remove cable guide -2- from steering column.

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

Gr. 80 ; Repairing heating

80 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Remove crash bar -A- by removing bolt -B-.

– Unbolt fuse holder beneath dash panel on left and lay to side

⇒ Electrical system; Rep. Gr. 97 ; Removing and installing fuse holder .

– Unhook relay carrier beneath dash panel on left and lay to side

⇒ Electrical system; Rep. Gr. 97 ; Removing and installing relay carrier .

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

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

– Pull off damping.

1. Repairing clutch mechanism 81

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Push damping upwards in area of upper securing nut -1-

above clutch pedal -A- in -direction of arrow-.

Remove mounting bracket securing nuts -arrows- as follows:

– Wrap tape around universal joint from socket set -V.A.G

1835- .

– Press wiring harness -1- upwards and left -arrow- using ex‐

tension -2- from -V.A.G 1835- .

– While doing this, unbolt upper securing nut for mounting brack‐

et.

– Then unbolt both lower securing nuts for mounting bracket and

remove mounting bracket.

1.16.2 Installing

Install in reverse order of removal. During this step, observe the following:

82 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

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

– Install relay carrier beneath dash panel on left ⇒ Electrical

system; Rep. Gr. 97 ; Removing and installing relay carrier .

– Install fuse holder beneath dash panel on left ⇒ Electrical

system; Rep. Gr. 97 ; Removing and installing fuse holder .

– Install crash bar -A-, tightening bolt -B- to specified torque

⇒ page 84 .

– Install footwell vent, cable guide, cover and compartment on

driver side ⇒ General body repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim panels .

– Renew cut cable ties.

– Push pipe/hose line -1- with seal -2- onto connection of master

cylinder -4- until securing clip -3- engages audibly.

– Test pipe/hose line by tugging on it.

– After removing hose clamp -3094- , return supply hose to its

original shape, if necessary.

– Bleed clutch system ⇒ page 101 .

– Install battery tray, battery cover and battery ⇒ Electrical sys‐

tem; Rep. Gr. 27 ; Removing and installing battery .

– If removed, install complete air filter housing ⇒ Rep. Gr. 23 ;

Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing injection system

1. Repairing clutch mechanism 83

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

1.16.3 Torque settings

Component Nm

Mounting bracket to bulkhead ♦ Renew self-locking nuts

Crash bar to steering column mounting bracket

♦ Renew bolts for crash bar

1.17 Removing and installing mounting bracket, Passat

Special tools and workshop equipment required

♦ Hose clamps to 25 mm -3094-

Bolt M8 = 20

25

Bolt M6 = 5

♦ Torque wrench -V.A.G 1331-

♦ Spring-type clip pliers -VAS 5024 A-

84 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

♦ Sealing tool -T10249-

1.17.1 Removing

LHD

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

theft code.

– Remove lower steering column trim ⇒ General body repairs,

interior; Rep. Gr. 68 ; Compartments, covers and trim panels .

– With ignition switched off, disconnect battery ⇒ Electrical sys‐

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

– Remove complete air filter housing if it is near battery ⇒ Rep.

Gr. 23 ; Repairing diesel direct injection system or ⇒ 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 longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.

♦

Place a lint-free cloth under the master cylinder.

– Clamp off supply hose to master cylinder using hose clamp

-3094- .

– If necessary, loosen spring-type clip -3- with assembly tool -

VAS 5024- and pull supply hose off master cylinder.

1. Repairing clutch mechanism 85

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– In addition, for disconnecting, you can close it with the sealing

tool -T10249/1- (⇒ figure above).

– Release securing clip -2- with a screwdriver or a pointed object

and pull out of master cylinder to stop.

– Pull pipe/hose line -1- out from master cylinder and seal hose.

– Separate electrical connector -4- at clutch position sender -

G476- .

– Remove driver side footwell cover ⇒ General body repairs,

interior; Rep. Gr. 68 ; Compartments, covers and trim panels .

– Remove crash bar -1- by removing bolt -2-.

– If present, remove retaining clip -1- and swing front parking aid

warning buzzer -H22- -2- in -direction of arrow-.

– Pull off damping if lower securing bolt for mounting bracket is

covered, -arrows-.

86 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Remove securing nuts -1- and -2-.

The upper securing nut -1- is accessible through the opening in the lower steering column trim.

– Pull mounting bracket -3- off studs on body.

1.17.2 Installing

Install in reverse order of removal. During this step, observe the following:

Note

♦

Renew self-locking nuts.

♦

Renew hose clips.

♦

– If present, install retaining clip for front parking aid warning

– Install crash bar -1- and tighten bolt -2- to specified torque

Allocate all components according to ⇒ Electronic parts cata‐ logue “ETKA” .

buzzer -H22- ⇒ Electrical system; Rep. Gr. 94 ; Parking aid .

⇒ page 88 .

– Install lower steering column trim ⇒ General body repairs, in‐

terior; Rep. Gr. 68 ; Compartments, covers and trim panels .

– Install driver side footwell cover ⇒ General body repairs, in‐

terior; Rep. Gr. 68 ; Compartments, covers and trim panels .

1. Repairing clutch mechanism 87

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Push pipe/hose line -1- with seal -2- onto connection of master

cylinder -4- until securing clip -3- engages audibly.

– Test line by tugging on it.

– After removing hose clamp -3094- , return supply hose to its

original shape, if necessary.

– Bleed clutch system ⇒ page 101 .

LHD

– Install battery tray, battery cover and battery ⇒ Electrical sys‐

tem; Rep. Gr. 27 ; Removing and installing battery .

– If removed, install complete air filter housing ⇒ Rep. Gr. 23 ;

Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing injection system

– Reconnect battery and perform work required after connecting

battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .

1.17.3 Torque settings

Component

Mounting bracket to bulkhead ♦ Renew self-locking nuts.

Crash bar ♦ Renew bolt for crash bar

1.18 Removing and installing master cylinder

Special tools and workshop equipment required

♦ Pliers -T10005-

Nm

25

20

1.18.1 Removing

– Remove mounting bracket, Golf 2004 ▸ ⇒ page 61 .

– Remove mounting bracket, Golf 2009 ▸ LHD ⇒ page 67 .

– Remove mounting bracket, Golf 2009 ▸ right-hand drive and

Golf Plus right-hand drive ⇒ page 73 .

– Remove mounting bracket, Golf Plus left-hand drive

⇒ page 79 .

– Remove mounting bracket, Passat ⇒ page 84

88 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Release retainer for master cylinder operating rod using pliers

-T10005- .

– Insert spacer -A- between clutch pedal and stop and press

clutch pedal to spacer.

♦

Length of spacer = about 40 mm (e.g. 1/2 socket).

– Release securing bar -B- and pull master cylinder out of

mounting bracket -arrow 1- and -arrow 2-.

1.18.2 Installing

• Move clutch pedal to rest position at stop.

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

1. Repairing clutch mechanism 89

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Insert spacer -A- between clutch pedal and stop and press

clutch pedal to spacer.

♦

Length of spacer = about 40 mm (e.g. 1/2 socket).

– Engage master cylinder in mounting bracket -arrow 1- and

-arrow 2-.

– Press master cylinder operating rod -1- in direction of arrow

until retainer -2- engages audibly in clutch pedal.

– Install mounting bracket, Golf 2004 ▸ ⇒ page 61 .

– Install mounting bracket, Golf 2009 ▸ LHD ⇒ page 67 .

– Install mounting bracket, Golf 2009 ▸ right-hand drive and Golf

Plus right-hand drive ⇒ page 73 .

– Install mounting bracket, Golf Plus left-hand drive

⇒ page 79 .

– Install mounting bracket, Passat ⇒ page 84

1.19 Removing and installing clutch position sender -G476-

Special tools and workshop equipment required

♦ Hose clamps -3094-

1.19.1 Removing

LHD

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

theft code.

– With ignition switched off, disconnect battery ⇒ Electrical sys‐

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

90 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

– Remove complete air filter housing if it is near battery ⇒ Rep.

Gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing injection system .

– Remove battery and battery tray ⇒ Electrical system; Rep.

Gr. 27 ; Battery; Removing and installing battery .

RHD

– In vehicles with particle filter, remove shielding -A- from parti‐

cle filter ⇒ Rep. Gr. 26 ; Parts of exhaust system; Assembly overview - front exhaust pipe with particle filter .

An insulation mat is installed in conjunction with some engines. Appearance may be different from that illustrated.

– Remove heat shield from pipe/hose line -arrows-.

Continuation for all

If a pipe/hose line -1- with a round component is installed directly beneath the master cylinder, the pipe/hose line must be removed.

Note

♦

During the following work, ensure that no brake fluid lands on longitudinal member or gearbox. If this does happen, clean the affected areas thoroughly.

♦

Place a lint-free cloth under the master cylinder.

1. Repairing clutch mechanism 91

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

– Clamp off supply hose to master cylinder using hose clamp

-3094- .

– Release securing clip -2- with a screwdriver or a pointed object

and pull out of master cylinder to stop.

– Pull pipe/hose line -1- out from master cylinder and seal hose.

– Disconnect electrical connector -4-.

– Unclip clutch position sender -G476- from master cylinder

-arrow- and remove.

1.19.2 Installing

Install in reverse order of removal. During this step, observe the following:

Note

♦

Renew hose clips.

♦

Allocate all components according to ⇒ Electronic parts cata‐ logue “ETKA” .

92 Rep. Gr.30 - Clutch

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ...

5-speed manual gearbox 0A4 - Edition 04.2010

If the pipe/hose line was removed

– Push pipe/hose line -1- with seal -2- onto connection of master

cylinder -4- until securing clip -3- engages audibly.

– Test pipe/hose line by tugging on it.

– After removing hose clamp -3094- , return supply hose to its

original position, if necessary.

– Bleed clutch system ⇒ page 101 .

Right-hand drive

– In vehicles with particle filter, install shielding -A- on particle

LHD

– Install battery tray and battery⇒ Electrical system; Rep. Gr.

– If removed, install complete air filter housing ⇒ Rep. Gr. 23 ;

– Reconnect battery and perform work required after connecting

filter ⇒ Rep. Gr. 26 ; Parts of exhaust system; Assembly overview - front exhaust pipe with particle filter .

27 ; Removing and installing battery .

Repairing diesel direct injection system or ⇒ Rep. Gr. 24 ; Repairing injection system

battery ⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and connecting battery .

1. Repairing clutch mechanism 93

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Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Golf Plus 2009 ➤ , Pass ... 5-speed manual gearbox 0A4 - Edition 04.2010

1.20 Assembly overview - hydraulics (LHD)

1 - Brake fluid reservoir

2 - Spring-type clip

❑ Not fitted in all vehicles

3 - Supply hose

❑ Rubber ❑ From 12. 05, plastic

⇒ page 95

❑ Golf 2009 ▸ and Golf

Plus 2009 ▸ plastic

⇒ page 95

4 - Master cylinder

❑ Removing and installing

⇒ page 88

5 - Clip

❑ Pull out clip to stop to re‐

move and install pipe/ hose line

6 - Retainer

❑ To remove and install,

separate master cylin‐ der from clutch pedal, Golf 2004 ▸ ⇒ page 38 , Golf 2009 ▸ ⇒ page 44 , Golf Plus ⇒ page 54 , Passat ⇒ page 59

7 - Clutch pedal

❑ Removing and instal‐

ling, Golf 2004 ▸

⇒ page 38

❑ Removing and instal‐

ling, Golf 2009 ▸

⇒ page 44

❑ Removing and instal‐

ling, Golf Plus ⇒ page 54

❑ Removing and installing, Passat ⇒ page 59

8 - Hexagon nut, ⇒ Item 15 (page 17)

9 - Seal / O-ring

❑ Pull onto line connection ❑ Insert with brake fluid ❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 95 ❑ Allocation ⇒ Electronic parts catalogue “ETKA”

10 - Pipe/hose line

❑ Allocation ⇒ Electronic parts catalogue “ETKA” ❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. Gr. 27 ; Removing and installing

battery .

11 - Retainer

❑ Secured to body

12 - Seal / O-ring

❑ Pull onto line connection ❑ Insert with brake fluid.

94 Rep. Gr.30 - Clutch

Volkswagen Golf Plus 2009 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

00 – Technical data

1 Gearbox identification

1.1 Location on gearbox

1.2 Identification codes, assembly allocation, capacities, Golf 2004 ▸

1.3 Identification codes, assembly allocation, capacities, Golf 2009 ▸

1.4 Identification codes, assembly allocation, capacities, Golf Plus 2005 ▸

1.5 Identification codes, assembly allocation, capacities, Golf Plus 2009 ▸

1.6 Identification codes, assembly allocation and capacities, Passat 2006 ▸

2 Overview - power transmission

3 Calculating overall gear ratio “i”

4 General repair notes

4.1 Components

4.1.1 Gearbox

4.1.2 Seals and sealing rings

4.1.3 Sealant

4.1.4 Locking devices

4.1.5 Nuts and bolts

4.1.6 Bearings

4.1.7 Shims

4.1.8 Synchro-rings

4.1.9 Gear wheels

4.1.10 Synchromeshed gears

4.1.11 Clutch

30 – Clutch

1 Repairing clutch mechanism

1.1 Overview

1.2 Assembly overview - pedal cluster

1.3 Removing and installing over-centre spring, Golf 2004 ▸

1.3.1 Removing

1.3.2 Installing

1.3.3 Torque settings

1.4.1 Removing

1.4.2 Installing

1.4.3 Torque settings

1.5.1 Removing

1.5.2 Installing

1.5.3 Torque settings

1.6 Removing and installing over-centre spring, Golf Plus

1.6.1 Removing

1.6.2 Installing

1.6.3 Torque settings

1.7 Removing and installing over-centre spring, Passat

1.7.1 Removing

1.7.2 Installing

1.8.1 Removing

1.8.2 Installing

1.8.3 Torque settings

1.9 Removing and installing clutch pedal, Golf 2009 ▸ LHD

1.9.1 Removing

1.9.2 Installing

1.9.3 Torque settings

1.10 Removing and installing clutch pedal, Golf 2009 ▸ RHD

1.10.1 Removing

1.10.2 Installing

1.10.3 Torque settings

1.11 Removing and installing clutch pedal, Golf Plus

1.11.1 Removing

1.11.2 Installing

1.11.3 Torque settings

1.12 Removing and installing clutch pedal, Passat

1.12.1 Removing

1.12.2 Installing

1.12.3 Torque setting

1.13 Removing and installing mounting bracket, Golf 2004 ▸

1.13.1 Removing

1.13.2 Installing

1.13.3 Torque settings

1.14 Removing and installing mounting bracket, Golf 2009 ▸ LHD

1.14.1 Removing

1.14.2 Installing

1.14.3 Torque settings

1.15 Removing and installing mounting bracket, Golf 2009 ▸ right-hand drive and Golf Plus right-hand drive

1.15.1 Removing

1.15.2 Installing

1.15.3 Torque settings

1.16 Removing and installing mounting bracket, Golf Plus left-hand drive