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MANUAL
March 24, 2019

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18. страница од 319
Golf 2004 , Golf 2009 , Golf
5-speed manual
Plus 2005 , Golf Plus 2009 ,
gearbox
4 General 0A4 - Edition
repair
To Pass
ensure ...
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19. страница од 319
Golf 2004 , Golf 2009 , Golf
5-speed manual
4.1.4 Locking Plus 2005 , Golf Plus 2009 ,
gearbox 0A4 - Edition
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devices
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20. страница од 319

Golf 2004 , Golf 2009 , Golf
5-speed manual
4.1.8Plus 2005 , Golf Plus 2009 ,
Synchro-
gearbox 0A4 - Edition
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grooves).

PDF OCR Transcript: Service Service Department.

Technical Information Workshop Manual Golf 2004
, Golf 2009 , Golf Plus 2005 , Golf Plus
2009 , Passat 2006 5-speed manual gearbox
0A4 Edition 04.2010 Protected by copyright.
Copying for private or commercial purposes, in
partor in whole, is not permitted unless authorised
by Volkswagen AG. Volkswagen AG does not
guarantee or accept any liability with respect to the
correctness ofinformation in this document.
Copyright by Volkswagen AG. List of Workshop
Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair
Groups Repair Group 00 - Technical data 30 -
Clutch 34 - Controls, housing 35 - Gears, shafts 39 -
Final drive - differential 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.
Protectepartor in whole, is not permitted unless
authorised by Volkswagen AG. Volkswagen AG
does not guarantee or accept any liability with
respect to the corrn ei, sesoprupl aicremmocr oe
tavirpr ofg inypoCt. hrigypocy bd AG. gen aswlkoVy
bt higrypoC. tnemucods ihtn in oitamrofnifos
senctService All rights reserved. No reproduction
without prior agreement from publisher. Copyright
© 2010 Volkswagen AG, Wolfsburg K0058990420
Protectepartor in whole, is not pGolf ermitted
un2004 less auth orise, d Golf by Volk2009
swagen AG. , 5-speed Golf Volkswagen Plus
manual 2005 AG doe gearbox s no, t Golf
guaranPlus 0A4 tee or ac2009 - ceEdition pt any
lia bility wit, h Pass 04.2010 respect to the co...
Contents 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 rrn
ei1.6 Identification codes, assembly allocation and
capacities, Passat 2006 ▸ . . . . . . . . . . . . . . 6 , 2 3 4
4.1 30 - Clutch 1 1.1 1.2 1.3 1.4 1.5 Overview
Calculating General Components . Repairing
Overview Assembly Removing Removing Removing
. . . sesoprupl airepair c. remm- . clutch overview
oand and and c. power r ooverall . e . ta. v. ir. p.
notes . installing installing installing r o. . .
fmechanism g . in. . transmission . ygear . p. . - o. C. .
pedal . t. . . . h. . ig. . ratio . over-centre over-centre
over-centre r. . y. . p. . . o. . cluster . c. . . . y “i” . b. . . .
. d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . spring, spring,
spring, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Golf Golf Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2004 2009 2009 AG. . . . . . . . . . . . . . . . . . . . . . gen .
. . . . . . . . . . . . . . ▸ ▸ ▸ . . a. . . . . . w. . . LHD RHD . . . . .
s. . . . . lk. . . . . . . o. . . . . . . V. . . . . . . . . y . . . . . b. . . . . .
. . t . . . . . h. . . . . . ig. . . . . . . . . . r. . . . . . y. . p. . . . . . . . .
. o. . . . C. . . . . . . . . . . . . . . . . t. . . n. . . . . . . e. . . . m. . . .
. . . . . . u. c. . . . . . . . . o. d. . . . . . . . . . . s ih. . . . . . . . . . t.
n i. . . . . . . . n . . . oit. . . . . a. . . . . m. ro. . . . f. . . . n. .
ifos . se. . n. . . . ct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
...............................................
. . 9 11 12 12 15 15 15 16 18 22 27 1.6 Removing and
installing over-centre spring, Golf Plus . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 32 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 1.9 l - 77 kW make turbo of diesel clutch,
engine vehicles . with . . . . 1.9 . . . l . - . 66 . . kW . . .
turbo . . . . . diesel . . . . . engine . . . . . and . . . .
vehicles . . . . . . with . . . . 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 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 Golf 2004 , Golf 2009
, Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-
speed manual gearbox 0A4 - Edition 04.2010 ii
Contents partor in whole, is not permitted unless
authorised by Volkswagen AG. Volkswagen AG
does not guarantee or accept any liability with
respect to the corrn ei, sesoprupl aicremmocr oe
tavirpr ofg inypoCt. higrypocy bd ProtecteAG. gen
awslkoVy bt higrypoC. tnemucods ihtn in
oitamrofnifos senct 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 Protected by copyright.
Copying for private or commercial purposes, in
partor in whole, is not permitted unless authorised
by Volkswagen AG. Volkswagen AG does not
guarantee or accept any liability with respect to the
correctness ofinformation in this document.
Copyright by Volkswagen AG. Contents iii Golf
2004 , Golf 2009 , Golf Plus 2005 , Golf
Plus 2009 , Pass ... 5-speed manual gearbox 0A4
- Edition 04.2010 partor in whole, is not permitted
unless authorised by Volkswagen AG. Volkswagen
AG does not guarantee or accept any liability with
respect to the corrn ei, iv Contents sesoprupl
aicremmocr oe tavirpr ofg inypoCt. higrypocy bd
ProtecteAG. agen wslkoVy bt higrypoC. tnemucods
ihtn in oitamrofnifos senct 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 I I I I I I I I Identification code Day Month
Year (2003) of manufacture Additional data provide
information about the production facility.
Protectepartor in whole, is not permitted unless
authorised by Volkswagen AG. Volkswagen AG
does not guarantee or accept any liability with
respect to the corrn ei, Note The gearbox code
sesoprupl aicremmocr oe is tavirpalso r ofg
inypincluded oCt. higrypocon y bd the vehicle data
stickers. AG. agen wslkoVy bt higrypoC. tnemucods
ihtn in oitamrofnifos sentc Golf 2004 , Golf 2009
, Golf Plus 2005 , Golf Plus 2009 , Pass ... 5-
speed manual gearbox 0A4 - Edition 04.2010 1.
Gearbox identification 1 1.2 Identification codes,
assembly allocation, capacities, Golf 2004 ▸ Manual
gearbox 5-speed 0A4 Identification code FNE GQQ
HGR Manufactured from08.03 08.03 03.05 to
08.03 08.06 08.06 Allocation Engine 1.9 l - 77 kW
1.9 l - 77 kW 2.5 l - 110 kW turbo diesel turbo diesel
Ratio Final drive 61 : 18 = 3.389 61 : 18 = 3.389 62 : 17
= 3.647 Z1 : Z2 Capacity of manual gearbox (gear‐
1.9 l 1.9 l 1.9 l box completely dismantled) Capacity
page 220 of manual (gearbox gearbox partially
dis‐ mantled) 1.7 l 1.7 l 1.7 l 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 HDR GTB JCT Manufactured
fromto 01.05 08.06 08.03 03.04 05.06 06.08
Allocation Engine 2.0 l - 85 kW 2.5 l - 110 kW 2.5 l -
110 kW Ratio Final drive 62 : 17 = 3.647 62 : 17 =
3.647 62 : 17 = 3.647 Z1 : Z2 Capacity box
completely of manual dismantled) gearbox (gear‐
1.9 l 1.9 l 1.9 l Capacity page 220 of manual
(gearbox gearbox partially dis‐ mantled) 1.7 l 1.7 l 1.7 l
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 from05.06 05.06 05.06 to 06.08
06.08 06.08 Allocation Engine 1.9 l - 66 kW 1.9
turbo l - diesel 77 kW turbo diesel 2.0 l - 85 kW 1.8 l
- 110 kW Golf 2004 , Golf 2009 , Golf Plus
2005 , Golf Plus 2009 , Pass ... 5-speed
manual gearbox 0A4 - Edition 04.2010 2 Rep. Gr.00
- Technical data partor in whole, is not permitted
unless authorised by Volkswagen AG. Volkswagen
AG does not guarantee or accept any liability with
respect to the corrn ei, sesoprupl aicremmocr oe
tavirpr ofg inypoCt. higrypocy bd ProtecteAG. agen
wslkoVy bt higrypoC. tnemucods ihtn in
oitamrofnifos sentc 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 box
completely of manual dismantled) gearbox (gear‐
1.9 l 1.9 l 1.9 l Capacity page 220 of manual
(gearbox gearbox partially dis‐ mantled) 1.7 l 1.7 l 1.7 l
Drive shaft flange 108 mm 100 mm 108 mm The
following data logue “ETKA” . Individual gear
Gear oil Clutch allocation Manual gearbox
Identification code Manufactured ratios can partor
in whbe ole, is not pfound ermitted ufromnlein ss to
authe thoris ed bElectronic y Volk05.06 12.06
FNC swagen parts AG. Volkswagen cata‐ AG does
not 5-speed 0A4 HJK 05.06 12.06 guarantee or
accept any liability w12.06 06.08 ith KCL respect to
the corAllocation Engine 1.9 l - 77 kW 1.8 l - 110 kW
1.9 l - 77 kW rn ei, Ratio Z1 : Z2 Capacity of manual
box completely Capacity of manual page 220
(gearbox mantled) Drive shaft flange The following
data logue “ETKA” . Individual gear Gear oil
dismantled) ratios can gearbox gearbox Final
sesopruppartially l aicbe remmocr ofound drive e
tavirp(gear‐ r odis‐ fg inin ypothe Ct. hig ry61
poElectronic turbo cy : 100 b18 d 1.9 1.7
Protectediesel = mm l l 3.778 parts cata‐ 63 : 16 =
3.938 1.9 l turbo diesel 61 : 18 = 3.778 1.9 l 1.7 l 100
mm AG. gen awslkoVy bt higrypoC. tnemucods ihtn
100 in oita1.7 mrofnifos semm ntcl Clutch
allocation Manual gearbox 5-speed 0A4
Identification code KBL KCD JQP Manufactured
fromto 07.07 06.08 05.07 12.07 07.07 06.08
Allocation Engine 1.9 turbo l - 77 diesel kW 2.5 l -
125 kW 1.8 l - 118 kW 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 mantled) page 220 (gearbox partially dis‐ Drive
shaft flange 100 mm 100 mm 100 mm 1. Gearbox
identification 3 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‐ from07.07
04.08 tured to 06.08 06.08 Allocation Engine 2.5 l -
125 kW 1.9 l - 77 kW turbo diesel Ratio Final drive 61
: 18 = 3.778 62 : 17 = 3.647 Z1 : Z2 Capacity of
manual gear‐ box (gearbox completely dismantled)
1.9 l 1.9 l Capacity of manual gear‐ box page 220
(gearbox partially dismantled) 1.7 l 1.7 l Drive shaft
flange 100 mm 100 mm The logue following
“ETKA” data . can be found in the Electronic parts
cata‐ 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‐ from06.08 08.08 05.09 tured to 05.09
Allocation Engine 1.9 l - 81 kW 2.0 l - 81 kW 1.6 l - 66
kW turbo diesel turbo diesel turbo diesel 1.6 turbo l
- 77 diesel kW Ratio Z1 : Z2 Final drive 61 : 18 = 3.778
61 : 18 = 3.778 62 : 17 = 3.647 Capacity of manual
gear‐ 1.9 l 1.9 l 1.9 l box dismantled) (gearbox
completely Capacity box page of manual 220
(gearbox gear‐ partially dismantled) 1.7 l 1.7 l 1.7 l
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 Golf 2004 , Golf 2009 , Golf Plus
2005 , Golf Plus 2009 , Pass ... 5-speed
manual gearbox 0A4 - Edition 04.2010 4 Rep. Gr.00
- Technical data partor in whole, is not permitted
unless authorised by Volkswagen AG. Volkswagen
AG does not guarantee or accept any liability with
respect to the corrn ei, sesoprupl aicremmocr oe
taivrpr ofg inypoC. thigrypocy bd ProtecteAG. agen
wslkoVy bt higrypoC. tnemucods ihtn in
oitamrofnifos sentc 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‐
from05.09 08.09 08.09 tured to 09.09 05.10
Allocation Engine 1.9 l - 77 kW 2.5 l - 125 kW 2.5 l -
125 kW turbo diesel Ratio Final drive 62 : 17 = 3.647
62 : 17 = 3.647 61 : 18 = 3.778 Z1 : Z2 Capacity of
manual gear‐ box (gearbox completely dismantled)
1.9 l 1.9 l 1.9 l Capacity of manual gear‐ 1.7 l 1.7 l 1.7 l
box partially page dismantled) 220 (gearbox
Drive shaft flange 100 mm 100 mm 100 mm The
logue following “ETKA” data . can be found in the
Electronic parts cata‐ partor in whole, is not
permitte d Manual Identification
Manufac‐ tured Allocation unleIndividual Gear
Clutch ss authorgearbox oil iseallocation d by gear
code Volkswratios agen Engine fromAG. to
Volkswagen 1.9 turbo AG 11.09 l MDZ - doe77 diesel
s nkW ot guarantee or accept any 2.5 lia5-speed
bility wl it05.10 08.10 h rLEA e- spect 125 to the
co0A4 kW rRatio Final drive 61 : 18 = 3.778 61 : 18 =
3.778 rn ei, sesoprupl aicremmocr oe tavirpThe
logue Z1 Capacity box dismantled) Capacity
box partially Drive r ofg inIndividual Gear :
yfollowing p(gearbox Z2 oC“ETKA” shaft page t.
higoil dismantled) of of rypflange omanual manual
220 cgear data y . completely bd Protecte(gearbox
gear‐ gear‐ can be found ratios 1.9 l 1.7 l 100 mm
in the Electronic parts AG. agen wslkoVy bt
higrypoC. tnemcata‐ ucods ihtn 100 in oita1.9 1.7
mrofnifos sentcmm l l Clutch allocation 1.4
Identification codes, assembly allocation,
capacities, Golf Plus 2005 ▸ Manual gearbox 5-
speed 0A4 Identification code HNV JCX KBL
Manufactured from11.04 05.06 11.07 to 05.06 01.09
01.09 1. Gearbox identification 5 Manual gearbox 5-
speed 0A4 Identification code HNV JCX KBL
Allocation Engine 1.9 l - 66 kW turbo diesel 1.9 turbo
l - 77 diesel kW 1.9 l - 66 kW turbo diesel 1.9 turbo l -
77 diesel kW 1.9 l - 77 kW turbo diesel Ratio Final
drive 62 : 17 = 3.647 62 : 17 = 3.647 61 : 18 = 3.778 Z1
: Z2 Capacity of manual gearbox 1.9 l 1.9 l 1.9 l
Capacity of manual gearbox page 220 (gearbox
partially dis‐ mantled) 1.7 l 1.7 l 1.7 l 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 from01.09 02.09 05.09 to
Allocation Engine 2.0 l - 81 kW 1.6 l - 66 kW turbo
diesel turbo diesel 1.6 turbo l - 77 diesel kW 1.9 l - 77
kW turbo diesel Ratio Final drive 61 : 18 = 3.778 62 :
17 = 3.647 62 : 17 = 3.647 Z1 : Z2 Capacity of manual
gearbox 1.9 l 1.9 l 1.9 l Capacity page 220 of
manual (gearbox gearbox partially dis‐ mantled) 1.7 l
1.7 l 1.7 l 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 1.6
Identification codes, assembly allocation and
capacities, Passat 2006 ▸ Manual gearbox 5-speed
0A4 Identification code HNV JCX JQP Manufac‐