VOLKSWAGEN PASSAT 2006 (02) PDF Document

The technical specifications for the VOLKSWAGEN PASSAT 2006 5-speed manual gearbox 0A4 with identification code JQF are as follows:

When installing the over-centre spring on the clutch pedal for a VOLKSWAGEN PASSAT 2006, check the operation of the over-centre spring by moving the mounting bracket up and down a few times after depressing the clutch pedal slightly, pushing the bolt through, and tightening the self-locking nut to the specified torque.

The specified torque for the clutch pedal to mounting bracket connection on a VOLKSWAGEN PASSAT 2006 is 25 Nm. When doing this, you must renew the self-locking nuts.

The specified torque for the crash bar to steering column mounting bracket connection (attachment with 1 bolt) when working on the clutch mechanism for a VOLKSWAGEN PASSAT 2006 is 20 Nm. You must renew the bolts for the crash bar.

The specified torque for the crash bar to steering column mounting bracket connection (attachment with 2 bolts) when working on the clutch mechanism for a VOLKSWAGEN PASSAT 2006 is 10 Nm. You must renew the bolts for the crash bar.

The special tool required for removing and installing the over-centre spring on the clutch pedal for a VOLKSWAGEN PASSAT 2006 is the Release tool -T10178-.

The procedure for removing the over-centre spring on the clutch pedal for a VOLKSWAGEN PASSAT 2006 is as follows:

Step 1. Remove mounting bracket.

Step 2. Carefully clamp the lower section of the clutch pedal in a vice with protective jaw pads.

Step 3. Separate the clutch pedal from the master cylinder.

Step 4. Press the over-centre spring from the clutch pedal -arrow 1- while swinging the mounting bracket in the -direction of arrow 2-.

Step 5. Carefully release the tension from the over-centre spring.

Step 6. Swing the mounting bracket back to the starting position and remove the over-centre spring.

The procedure for installing the over-centre spring on the clutch pedal for a VOLKSWAGEN PASSAT 2006 is as follows:

Step 1. Carefully clamp the lower section of the clutch pedal in a vice with protective jaw pads.

Step 2. Insert the over-centre spring in the mounting bracket.

Step 3. The receptacle -arrow- for the tip -A- of the clutch pedal must stand vertically.

Step 4. Insert the tip of the clutch pedal in the bearing recess of the over-centre spring.

Step 5. Compress the over-centre spring -arrow 1-.

Step 6. At the same time, move the mounting bracket downwards -arrow 2- until the over-centre spring can be pressed onto the locating lug -A- of the clutch pedal.

Step 7. Connect the clutch pedal to the master cylinder.

Step 8. Install the mounting bracket.

The gearbox oil capacity for a completely dismantled VOLKSWAGEN PASSAT 2006 5-speed manual gearbox 0A4 is 1.9 l.

The gearbox oil capacity for a partially dismantled VOLKSWAGEN PASSAT 2006 5-speed manual gearbox 0A4 is 1.7 l (refer to gearbox oil capacity information on page 220 for details on partially dismantled gearboxes).

It is not possible to check the gear oil level by unscrewing the oil filler plug for the VOLKSWAGEN PASSAT 2006. The oil level in the gearbox can only be checked by completely draining the gear oil and then refilling, observing the following table regarding checking and topping up gear oil:

The general repair notes regarding seals and sealing rings for the gearbox on the VOLKSWAGEN PASSAT 2006 are as follows:

Step 1. Before installing the oil seal, half-fill the space between the sealing lips with sealing grease -G 052 128 A1- (arrow).

Step 2. The open side of the oil seal faces the side with fluid filling.

Step 3. After installing, check the oil level.

Step 4. Lightly oil O-rings before installing; this prevents the rings from being crushed when inserted.

Step 5. Thoroughly clean parting surfaces and apply sealant -AMV 188 200 03-.

Step 6. Apply sealant uniformly but not too thick.

The torque settings for the gearbox mounting components on the VOLKSWAGEN PASSAT 2006 when reinstalling the gearbox are as follows:

The procedure to drain the gear oil from the VOLKSWAGEN PASSAT 2006 gearbox is as follows:

Step 1. Clean the gearbox.

Step 2. To drain the gear oil, a pivot pin for the selector forks in the gearbox must be removed. To prevent the positions of the selector forks from being changed (e.g. due to accidental operation of the selector mechanism), the selector shaft must be locked in position.

Step 3. Secure the selector shaft by pressing the selector shaft down -direction of arrow 1-.

Step 4. While pressing down the selector shaft, turn the angled rod -A- upwards in -direction of arrow 2- and at the same time press it in until it engages in the selector shaft.

Step 5. Use a clean container with a scale and a 3-litre capacity to catch the oil which runs out. The selector shaft is locked in place.

Step 6. Drain the gear oil by removing the oil drain plug -arrow 1- and then the pivot pin -arrow 2-.

Step 7. Install the pivot pin -arrow 2- with a new O-ring.

Step 8. Screw in the oil drain plug -arrow 1-.

Step 9. Now turn the angled rod -A- back to its original position -direction of arrow- so that the selector shaft can move again.

The procedure for bleeding the clutch system after installing the slave cylinder on the VOLKSWAGEN PASSAT 2006 is as follows:

Step 1. Bleed the clutch system.

Step 2. If removed, install the complete air filter housing.

Step 3. Reconnect the battery and perform work required after connecting the battery.

To check the operation of the selector mechanism after filling the gearbox with gear oil on the VOLKSWAGEN PASSAT 2006:

Step 1. Install the reversing light switch -F4- -arrow-.

Step 2. Check the operation of the selector mechanism.

Step 3. Install the complete air filter housing.

Step 4. Install the noise insulation.