2008-2013 Volkswagen Golf MK6 Factory Service Manual – PDF DOWNLOAD
DESCRIPTION:
2008-2013 Volkswagen Golf MK6 Factory Service Manual – PDF DOWNLOAD
Language : English
Pages : 7208
Downloadable : Yes
File Type : PDF
Size: 261 MB
TABLE OF CONTENTS:
2008-2013 Volkswagen Golf MK6 Factory Service Manual – PDF DOWNLOAD
Cover.pdf (p.1)..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1
Contents.pdf (p.2).................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 2
00-Maintenance & General Info.pdf (p.3-794)......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3
00-01 Fluid Capacity Tables..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3
03 – Maintenance, Diagnosis................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7
1 CC.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7
2 Eos................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9
3 Golf/GTI.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 10
4 Jetta................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 12
5 Jetta SportWagen/Golf Wagon........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 14
6 Tiguan................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 15
7 Touareg............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 16
8 Routan................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 18
00-02 Maintenance Intervals..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 22
03 – Maintenance, Diagnosis................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 26
1 MY 2015 Maintenance Intervals ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 26
1.1 MY 2015 Maintenance Intervals - USA............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 26
1.1.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 26
1.1.2 Service at 20,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 27
1.1.3 Service at 30,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 27
1.1.4 Service at 40,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 28
1.1.5 Service at 50,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 29
1.1.6 Service at 60,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 29
1.1.7 Service at 70,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 30
1.1.8 Service at 80,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 31
1.1.9 Service at 90,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 32
1.1.10 Service at 100,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 32
1.1.11 Service at 110,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 33
1.1.12 Service at 120,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 33
1.1.13 Service at 130,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 35
1.1.14 Service at 140,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 35
1.1.15 Service at 150,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 36
1.1.16 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 36
1.1.17 Brake Fluid Replacement.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 37
1.2 MY 2015 Maintenance Intervals - Canada.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 37
1.2.1 Service at 15.000€kilometres.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 38
1.2.2 Service at 30.000€kilometres.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 38
1.2.3 Service at 45.000€kilometres.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 39
1.2.4 Service at 60.000€kilometres.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 40
1.2.5 Service at 75.000€kilometres.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 41
1.2.6 Service at 90.000€kilometres.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 42
1.2.7 Service at 105.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 42
1.2.8 Service at 120.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 43
1.2.9 Service at 135.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 44
1.2.10 Service at 150.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 45
1.2.11 Service at 165.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 46
1.2.12 Service at 180.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 47
1.2.13 Service at 195.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 48
1.2.14 Service at 210.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 49
1.2.15 Service at 225.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 49
1.2.16 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 50
1.2.17 Brake Fluid Replacement.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 51
1.3 MY 2015 Maintenance Intervals - e-Golf.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 51
1.3.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 51
1.3.2 Service at 20,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 52
1.3.3 Service at 30,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 52
1.3.4 Service at 40,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 53
1.3.5 Service at 50,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 54
1.3.6 Service at 60,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 54
1.3.7 Service at 70,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 55
1.3.8 Service at 80,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 56
1.3.9 Service at 90,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 57
1.3.10 Service at 100,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 57
1.3.11 Service at 110,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 58
1.3.12 Service at 120,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 58
1.3.13 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 59
1.3.14 Brake Fluid Replacement.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 60
2 MY 2014 Maintenance Intervals ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 61
2.1 MY 2014 Maintenance Intervals (All Vehicles Except Touareg and Routan) - USA.................................................................................................................................................................................................................................................................................................................................................................................................................................... 61
2.1.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 61
2.1.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 62
2.1.3 Service at 30,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 62
2.1.4 Service at 40,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 63
2.1.5 Service at 50,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 64
2.1.6 Service at 60,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 64
2.1.7 Service at 70,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 65
2.1.8 Service at 80,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 66
2.1.9 Service at 90,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 67
2.1.10 Service at 100,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 67
2.1.11 Service at 110,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 68
2.1.12 Service at 120,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 68
2.1.13 Service at 130,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 70
2.1.14 Service at 140,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 70
2.1.15 Service at 150,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 71
2.1.16 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 71
2.1.17 Brake Fluid Replacement.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 72
2.2 MY 2014 Maintenance Intervals (Touareg Only) - USA.............................................................................................................................................................................................................................................................................................................................................................................................................................................................. 73
2.2.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 73
2.2.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 73
2.2.3 Service at 30,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 74
2.2.4 Service at 40,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 74
2.2.5 Service at 50,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 76
2.2.6 Service at 60,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 76
2.2.7 Service at 70,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 77
2.2.8 Service at 80,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 77
2.2.9 Service at 90,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 78
2.2.10 Service at 100,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 79
2.2.11 Service at 110,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 79
2.2.12 Service at 120,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 80
2.2.13 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 81
2.2.14 Brake Fluid Replacement.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 81
2.3 MY 2014 Maintenance Intervals (Only Jetta, Jetta GLI, Jetta Hybrid, The Beetle, The Beetle Convertible, and Golf Wagon) - Canada................................................................................................................................................................................................................................................................................................................................................................................ 82
2.3.1 Service at 15.000€kilometres.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 82
2.3.2 Service at 30.000€kilometres.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 83
2.3.3 Service at 45.000€kilometres.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 84
2.3.4 Service at 60.000€kilometres.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 84
2.3.5 Service at 75.000€kilometres.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 86
2.3.6 Service at 90.000€kilometres.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 86
2.3.7 Service at 105.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 87
2.3.8 Service at 120.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 88
2.3.9 Service at 135.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 89
2.3.10 Service at 150.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 90
2.3.11 Service at 165.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 91
2.3.12 Service at 180.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 91
2.3.13 Service at 195.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 93
2.3.14 Service at 210.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 94
2.3.15 Service at 225.000€kilometres............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 94
2.3.16 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 95
2.3.17 Brake Fluid Replacement.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 96
3 MY 2013 Maintenance Intervals ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 97
3.1 MY 2013 Maintenance Intervals (All Vehicles Except Touareg and Routan) - USA.................................................................................................................................................................................................................................................................................................................................................................................................................................... 97
3.1.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 97
3.1.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 98
3.1.3 Service at 30,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 98
3.1.4 Service at 40,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 99
3.1.5 Service at 50,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 100
3.1.6 Service at 60,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 100
3.1.7 Service at 70,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 101
3.1.8 Service at 80,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 101
3.1.9 Service at 90,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 102
3.1.10 Service at 100,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 103
3.1.11 Service at 110,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 103
3.1.12 Service at 120,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 104
3.1.13 Service at 130,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 105
3.1.14 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 105
3.1.15 Brake Fluid Replacement.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 106
3.2 MY 2013 Maintenance Intervals (Touareg Only) - USA.............................................................................................................................................................................................................................................................................................................................................................................................................................................................. 107
3.2.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 107
3.2.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 107
3.2.3 Service at 30,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 108
3.2.4 Service at 40,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 109
3.2.5 Service at 50,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 110
3.2.6 Service at 60,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 110
3.2.7 Service at 70,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 111
3.2.8 Service at 80,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 111
3.2.9 Service at 90,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 112
3.2.10 Service at 100,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 113
3.2.11 Service at 110,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 113
3.2.12 Service at 120,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 114
3.2.13 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 115
3.2.14 Brake Fluid Replacement.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 115
3.3 MY 2013 Maintenance Intervals (All Vehicles) - Canada........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 116
3.3.1 Service at 15.000€km...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 116
3.3.2 Service at 30.000€km...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 117
3.3.3 Service at 60.000€km...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 118
3.3.4 Service at 75.000€km...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 119
3.3.5 Service at 90.000€km...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 119
3.3.6 Service at 105.000€km..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 120
3.3.7 Service at 120.000€km..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 121
3.3.8 Service at 135.000€km..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 122
3.3.9 Service at 150.000€km..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 123
3.3.10 Service at 165.000€km.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 124
3.3.11 Service at 180.000€km.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 124
3.3.12 Service at 195.000€km.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 126
3.3.13 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 126
3.3.14 Brake Fluid Replacement.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 127
4 MY 2012 Maintenance Intervals ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 128
4.1 MY 2012 Maintenance Intervals (All Vehicles Except Touareg and Routan) - USA.................................................................................................................................................................................................................................................................................................................................................................................................................................... 128
4.1.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 128
4.1.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 129
4.1.3 Service at 30,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 129
4.1.4 Service at 40,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 130
4.1.5 Service at 50,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 131
4.1.6 Service at 60,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 131
4.1.7 Service at 70,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 132
4.1.8 Service at 80,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 132
4.1.9 Service at 90,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 133
4.1.10 Service at 100,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 134
4.1.11 Service at 110,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 134
4.1.12 Service at 120,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 135
4.1.13 Service at 130,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 136
4.1.14 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 136
4.1.15 Brake Fluid Replacement.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 137
4.2 MY 2012 Maintenance Intervals (Touareg Only) - USA.............................................................................................................................................................................................................................................................................................................................................................................................................................................................. 138
4.2.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 138
4.2.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 138
4.2.3 Service at 30,000€miles (Included in the Volkswagen Carefree Maintenance Program)......................................................................................................................................................................................................................................................................................................................................................................................................................... 139
4.2.4 Service at 40,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 140
4.2.5 Service at 50,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 141
4.2.6 Service at 60,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 141
4.2.7 Service at 70,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 142
4.2.8 Service at 80,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 142
4.2.9 Service at 90,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 143
4.2.10 Service at 100,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 144
4.2.11 Service at 110,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 144
4.2.12 Service at 120,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 145
4.2.13 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 146
4.2.14 Brake Fluid Replacement.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 146
4.3 MY 2012 Maintenance Intervals - Canada.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 147
4.3.1 Service at 15.000€km...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 147
4.3.2 Service at 30.000€km...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 148
4.3.3 Service at 45.000€km...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 149
4.3.4 Service at 60.000€km...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 149
4.3.5 Service at 75.000€km...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 150
4.3.6 Service at 90.000€km...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 151
4.3.7 Service at 105.000€km..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 152
4.3.8 Service at 120.000€km..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 152
4.3.9 Service at 135.000€km..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 154
4.3.10 Service at 150.000€km.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 154
4.3.11 Service at 165.000€km.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 155
4.3.12 Service at 180.000€km.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 156
4.3.13 Service at 195.000€km.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 157
4.3.14 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 158
4.3.15 Brake Fluid Replacement.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 158
4.4 MY 2012 Maintenance Intervals - Routan - USA.................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 159
4.4.1 Service at 8,000 Miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 159
4.4.2 Service at 16,000 Miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 159
4.4.3 Service at 24,000 Miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 160
4.4.4 Service at 32,000 Miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 160
4.4.5 Service at 40,000 Miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 160
4.4.6 Service at 48,000 Miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 160
4.4.7 Service at 56,000 Miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 160
4.4.8 Service at 64,000 Miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 161
4.4.9 Service at 72,000 Miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 161
4.4.10 Service at 80,000 Miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 161
4.4.11 Service at 88,000 Miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 161
4.4.12 Service at 96,000 Miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 162
4.4.13 Service at 104,000 Miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 162
4.4.14 Service at 112,000 Miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 162
4.4.15 Service at 120,000 Miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 162
4.4.16 Service at 128,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 163
4.4.17 Service at 136,000 Miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 163
4.4.18 Service at 144,000 Miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 163
4.4.19 Service at 152,000 Miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 163
4.5 MY 2012 Maintenance Intervals - Routan - Canada................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 164
4.5.1 Service at 13,000 Kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 164
4.5.2 Service at 26,000 Kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 164
4.5.3 Service at 39,000 Kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 164
4.5.4 Service at 52,000 Kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 165
4.5.5 Service at 65,000Kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 165
4.5.6 Service at 78,000 Kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 165
4.5.7 Service at 91,000 Kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 165
4.5.8 Service at 104,000 Kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 165
4.5.9 Service at 117,000 Kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 166
4.5.10 Service at 130,000 Kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 166
4.5.11 Service at 143,000 Kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 166
4.5.12 Service at 156,000 Kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 166
4.5.13 Service at 169,000 Kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 167
4.5.14 Service at 182,000 Kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 167
4.5.15 Service at 195,000 Kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 167
4.5.16 Service at 208,000 Kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 167
4.5.17 Service at 221,000 Kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 167
4.5.18 Service at 234,000 Kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 167
4.5.19 Service at 247,000 Kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 168
5 MY 2011 Maintenance Intervals......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 169
5.1 MY 2011 Maintenance Intervals (Except Routan) - USA............................................................................................................................................................................................................................................................................................................................................................................................................................................................. 169
5.1.1 Time Dependent Service.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 169
5.1.2 Service at 10,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 170
5.1.3 Service at 20,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 170
5.1.4 Service at 30,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 171
5.1.5 Service at 40,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 172
5.1.6 Service at 50,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 173
5.1.7 Service at 60,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 173
5.1.8 Service at 70,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 174
5.1.9 Service at 80,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 175
5.1.10 Service at 90,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 176
5.1.11 Service at 100,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 177
5.1.12 Service at 110,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 177
5.1.13 Service at 120,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 178
5.1.14 Service at 130,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 179
5.2 MY 2011 Maintenance Intervals (Except Routan) - Canada.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 180
5.2.1 Time Dependent Service.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 180
5.2.2 Service at 15,000€kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 181
5.2.3 Service at 30,000€kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 182
5.2.4 Service at 45,000€kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 182
5.2.5 Service at 60,000€kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 183
5.2.6 Service at 75,000€kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 184
5.2.7 Service at 90,000€kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 185
5.2.8 Service at 105,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 186
5.2.9 Service at 120,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 186
5.2.10 Service at 135,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 188
5.2.11 Service at 150,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 188
5.2.12 Service at 165,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 189
5.2.13 Service at 180,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 190
5.2.14 Service at 195,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 191
5.3 MY 2011 Maintenance Intervals - Routan - USA.................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 193
5.3.1 Service at 8,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 193
5.3.2 Service at 16,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 193
5.3.3 Service at 24,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 193
5.3.4 Service at 32,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 194
5.3.5 Service at 40,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 194
5.3.6 Service at 48,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 194
5.3.7 Service at 56,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 194
5.3.8 Service at 64,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 194
5.3.9 Service at 72,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 195
5.3.10 Service at 80,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 195
5.3.11 Service at 88,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 195
5.3.12 Service at 96,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 195
5.3.13 Service at 104,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 196
5.3.14 Service at 112,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 196
5.3.15 Service at 120,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 196
5.3.16 Service at 128,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 196
5.3.17 Service at 136,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 196
5.3.18 Service at 144,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 196
5.3.19 Service at 152,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 197
5.4 MY 2011 Maintenance Intervals - Routan - Canada................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 197
5.4.1 Service at 13,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 197
5.4.2 Service at 26,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 198
5.4.3 Service at 39,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 198
5.4.4 Service at 52,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 198
5.4.5 Service at 65,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 198
5.4.6 Service at 78,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 198
5.4.7 Service at 91,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 199
5.4.8 Service at 104,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 199
5.4.9 Service at 117,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 199
5.4.10 Service at 130,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 199
5.4.11 Service at 143,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 200
5.4.12 Service at 156,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 200
5.4.13 Service at 169,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 200
5.4.14 Service at 182,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 200
5.4.15 Service at 195,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 200
5.4.16 Service at 208,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 201
5.4.17 Service at 221,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 201
5.4.18 Service at 234,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 201
5.4.19 Service at 247,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 201
6 MY 2010 Maintenance Intervals......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 202
6.1 MY 2010 Maintenance Intervals - USA............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 202
6.1.1 Time Dependent Service.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 202
6.1.2 Service at Each 5,000 miles through 35,000 miles.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 203
6.1.3 Service at 10,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 203
6.1.4 Service at 20,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 203
6.1.5 Service at 30,000€miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 204
6.1.6 Service at 40,000€miles and each 5,000 miles After........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 204
6.1.7 Service at 40,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 204
6.1.8 Service at 50,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 206
6.1.9 Service at 60,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 206
6.1.10 Service at 70,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 207
6.1.11 Service at 80,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 207
6.1.12 Service at 90,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 208
6.1.13 Service at 100,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 209
6.1.14 Service at 110,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 209
6.1.15 Service at 120,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 210
6.2 MY 2010 Maintenance Intervals - Canada.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 211
6.2.1 Time Dependent Service.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 211
6.2.2 Service at 15,000€kilometers or one year from vehicle in-service date..................................................................................................................................................................................................................................................................................................................................................................................................................................... 212
6.2.3 Service at 30,000€kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 212
6.2.4 Service at 45,000€kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 213
6.2.5 Service at 60,000€kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 213
6.2.6 Service at 75,000€kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 215
6.2.7 Service at 90.000€kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 215
6.2.8 Service at 105,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 216
6.2.9 Service at 120,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 216
6.2.10 Service at 135,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 217
6.2.11 Service at 150,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 218
6.2.12 Service at 165,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 218
6.2.13 Service at 180,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 219
6.3 MY 2010 Maintenance Intervals - Routan - USA.................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 220
6.3.1 Service at 6,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 221
6.3.2 Service at 12,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 221
6.3.3 Service at 18,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 221
6.3.4 Service at 24,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 222
6.3.5 Service at 30,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 222
6.3.6 Service at 36,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 222
6.3.7 Service at 42,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 222
6.3.8 Service at 48,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 222
6.3.9 Service at 54,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 222
6.3.10 Service at 60,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 223
6.3.11 Service at 66,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 223
6.3.12 Service at 72,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 223
6.3.13 Service at 78,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 223
6.3.14 Service at 84,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 223
6.3.15 Service at 90,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 223
6.3.16 Service at 96,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 224
6.3.17 Service at 102,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 224
6.3.18 Service at 108,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 224
6.3.19 Service at 114,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 224
6.3.20 Service at 120,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 224
6.3.21 Service at 126,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 225
6.3.22 Service at 132,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 225
6.3.23 Service at 138,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 225
6.3.24 Service at 144,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 225
6.3.25 Service at 150,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 225
6.4 MY 2010 Maintenance Intervals - Routan - Canada................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 226
6.4.1 Service at 10,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 226
6.4.2 Service at 20,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 226
6.4.3 Service at 30,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 227
6.4.4 Service at 40,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 227
6.4.5 Service at 50,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 227
6.4.6 Service at 60,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 227
6.4.7 Service at 70,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 227
6.4.8 Service at 80,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 227
6.4.9 Service at 90,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 227
6.4.10 Service at 100,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 228
6.4.11 Service at 110,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 228
6.4.12 Service at 120,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 228
6.4.13 Service at 130,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 228
6.4.14 Service at 140,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 228
6.4.15 Service at 150,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 228
6.4.16 Service at 160,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 229
6.4.17 Service at 170,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 229
6.4.18 Service at 180,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 229
6.4.19 Service at 190,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 229
6.4.20 Service at 200,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 229
6.4.21 Service at 210,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 230
6.4.22 Service at 220,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 230
6.4.23 Service at 230,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 230
6.4.24 Service at 240,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 230
6.4.25 Service at 250,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 230
7 MY 2009 Maintenance Intervals......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 231
7.1 MY 2009 Maintenance Intervals - USA............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 231
7.1.1 Time-Dependent Maintenance Items.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 231
7.1.2 Service every 5,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 232
7.1.3 Service at 10,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 232
7.1.4 Service at 20,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 232
7.1.5 Service at 30,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 233
7.1.6 Service at 40,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 233
7.1.7 Service at 50,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 234
7.1.8 Service at 60,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 235
7.1.9 Service at 70,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 235
7.1.10 Service at 80,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 236
7.1.11 Service at 90,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 237
7.1.12 Service at 100,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 237
7.1.13 Service at 110,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 238
7.1.14 Service at 120,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 238
7.1.15 Service at 130,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 239
7.2 MY 2009 Maintenance Intervals - Canada.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 240
7.2.1 Time Dependent Service.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 240
7.2.2 Service at 15,000€kilometers or one year from vehicle in-service date..................................................................................................................................................................................................................................................................................................................................................................................................................................... 241
7.2.3 Service at 30,000€kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 241
7.2.4 Service at 45,000€kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 242
7.2.5 Service at 60,000€kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 242
7.2.6 Service at 75,000€kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 243
7.2.7 Service at 90.000€kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 244
7.2.8 Service at 105,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 244
7.2.9 Service at 120,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 245
7.2.10 Service at 135,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 246
7.2.11 Service at 150,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 247
7.2.12 Service at 165,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 247
7.2.13 Service at 180,000€kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 248
7.3 MY 2009 Maintenance Intervals - Routan - USA.................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 249
7.3.1 Service at 6,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 250
7.3.2 Service at 12,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 250
7.3.3 Service at 18,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 250
7.3.4 Service at 24,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 251
7.3.5 Service at 30,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 251
7.3.6 Service at 36,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 251
7.3.7 Service at 42,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 251
7.3.8 Service at 48,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 251
7.3.9 Service at 54,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 251
7.3.10 Service at 60,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 251
7.3.11 Service at 66,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 252
7.3.12 Service at 72,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 252
7.3.13 Service at 78,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 252
7.3.14 Service at 84,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 252
7.3.15 Service at 90,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 252
7.3.16 Service at 96,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 252
7.3.17 Service at 102,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 253
7.3.18 Service at 108,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 253
7.3.19 Service at 114,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 253
7.3.20 Service at 120,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 253
7.3.21 Service at 126,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 253
7.3.22 Service at 132,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 253
7.3.23 Service at 138,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 253
7.3.24 Service at 144,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 254
7.3.25 Service at 150,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 254
7.4 MY 2009 Maintenance Intervals - Routan - Canada................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 254
7.4.1 Service at 10,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 254
7.4.2 Service at 20,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 255
7.4.3 Service at 30,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 255
7.4.4 Service at 40,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 255
7.4.5 Service at 50,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 255
7.4.6 Service at 60,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 255
7.4.7 Service at 70,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 255
7.4.8 Service at 80,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 255
7.4.9 Service at 90,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 256
7.4.10 Service at 100,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 256
7.4.11 Service at 110,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 256
7.4.12 Service at 120,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 256
7.4.13 Service at 130,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 256
7.4.14 Service at 140,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 256
7.4.15 Service at 150,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 256
7.4.16 Service at 160,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 257
7.4.17 Service at 170,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 257
7.4.18 Service at 180,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 257
7.4.19 Service at 190,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 257
7.4.20 Service at 200,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 257
7.4.21 Service at 210,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 258
7.4.22 Service at 220,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 258
7.4.23 Service at 230,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 258
7.4.24 Service at 240,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 258
7.4.25 Service at 250,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 258
8 MY 2008 Maintenance Intervals......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 259
8.1 MY 2008 Maintenance Intervals - USA............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 259
8.1.1 Time-Dependent Maintenance Items.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 259
8.1.2 Service at 5,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 259
8.1.3 Service at 10,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 260
8.1.4 Service at 20,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 260
8.1.5 Service at 30,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 261
8.1.6 Service at 40,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 261
8.1.7 Service at 50,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 263
8.1.8 Service at 60,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 263
8.1.9 Service at 70,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 264
8.1.10 Service at 80,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 265
8.1.11 Service at 90,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 266
8.1.12 Service at 100,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 267
8.1.13 Service at 110,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 268
8.1.14 Service at 120,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 268
8.2 MY 2008 Maintenance Intervals - Canada.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 270
8.2.1 Time-Dependent Maintenance Items.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 270
8.2.2 Service at 8,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 270
8.2.3 Service at 16,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 270
8.2.4 Service at 32,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 271
8.2.5 Service at 48,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 272
8.2.6 Service at 64,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 272
8.2.7 Service at 80,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 274
8.2.8 Service at 96,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 274
8.2.9 Service at 112,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 275
8.2.10 Service at 128,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 276
8.2.11 Service at 144,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 277
8.2.12 Service at 160,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 277
8.2.13 Service at 176,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 278
8.2.14 Service at 180,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 279
9 MY 2007 Maintenance Intervals......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 281
9.1 MY 2007 Maintenance Intervals - USA............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 281
9.1.1 Time-Dependent Maintenance Items.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 281
9.1.2 Service at 5,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 282
9.1.3 Service at 10,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 282
9.1.4 Service at 20,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 282
9.1.5 Service at 30,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 283
9.1.6 Service at 40,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 283
9.1.7 Service at 50,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 284
9.1.8 Service at 60,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 285
9.1.9 Service at 70,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 286
9.1.10 Service at 80,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 286
9.1.11 Service at 90,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 287
9.1.12 Service at 100,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 288
9.1.13 Service at 110,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 289
9.1.14 Service at 120,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 289
9.2 MY 2007 Maintenance Intervals - Canada.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 291
9.2.1 Time-Dependent Maintenance Items.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 291
9.2.2 Service at 8,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 291
9.2.3 Service at 16,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 292
9.2.4 Service at 32,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 292
9.2.5 Service at 48,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 293
9.2.6 Service at 64,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 293
9.2.7 Service at 80,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 294
9.2.8 Service at 96,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 295
9.2.9 Service at 112,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 296
9.2.10 Service at 128,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 296
9.2.11 Service at 144,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 297
9.2.12 Service at 160,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 297
9.2.13 Service at 176,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 298
9.2.14 Service at 180,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 299
10 MY 2006 Maintenance Intervals........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 301
10.1 MY 2006 Maintenance Intervals - USA............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 301
10.1.1 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 301
10.1.2 Service at 5,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 302
10.1.3 Service at 10,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 302
10.1.4 Service at 15,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 302
10.1.5 Service at 20,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 302
10.1.6 Service at 25,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 303
10.1.7 Service at 30,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 303
10.1.8 Service at 35,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 304
10.1.9 Service at 40,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 304
10.1.10 Service at 45,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 305
10.1.11 Service at 50,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 305
10.1.12 Service at 55,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 306
10.1.13 Service at 60,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 306
10.1.14 Service at 65,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 307
10.1.15 Service at 70,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 307
10.1.16 Service at 75,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 307
10.1.17 Service at 80,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 307
10.1.18 Service at 85,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 309
10.1.19 Service at 90,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 309
10.1.20 Service at 95,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 309
10.1.21 Service at 100,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 309
10.1.22 Service at 105,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 310
10.2 MY 2006 Maintenance Intervals - Canada......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 311
10.2.1 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 311
10.2.2 Service at 8,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 312
10.2.3 Service at 16,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 312
10.2.4 Service at 24,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 312
10.2.5 Service at 32,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 312
10.2.6 Service at 40,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 313
10.2.7 Service at 48,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 313
10.2.8 Service at 56,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 314
10.2.9 Service at 64,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 314
10.2.10 Service at 72,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 315
10.2.11 Service at 80,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 315
10.2.12 Service at 88,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 316
10.2.13 Service at 96,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 316
10.2.14 Service at 104,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 317
10.2.15 Service at 112,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 317
10.2.16 Service at 120,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 317
10.2.17 Service at 128,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 317
10.2.18 Service at 136,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 319
10.2.19 Service at 144,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 319
10.2.20 Service at 152,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 319
10.2.21 Service at 160,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 319
10.2.22 Service at 168,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 320
11 MY 2005 Maintenance Intervals........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 321
11.1 MY 2005 Maintenance Intervals - USA............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 321
11.1.1 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 321
11.1.2 Service at 5,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 322
11.1.3 Service at 10,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 322
11.1.4 Service at 15,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 322
11.1.5 Service at 20,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 322
11.1.6 Service at 25,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 323
11.1.7 Service at 30,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 323
11.1.8 Service at 35,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 324
11.1.9 Service at 40,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 324
11.1.10 Service at 45,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 325
11.1.11 Service at 50,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 325
11.1.12 Service at 55,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 325
11.1.13 Service at 60,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 326
11.1.14 Service at 65,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 327
11.1.15 Service at 70,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 327
11.1.16 Service at 75,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 327
11.1.17 Service at 80,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 327
11.1.18 Service at 85,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 328
11.1.19 Service at 90,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 328
11.1.20 Service at 95,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 329
11.1.21 Service at 100,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 329
11.1.22 Service at 105,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 330
11.2 MY 2005 Maintenance Intervals - Canada......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 331
11.2.1 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 331
11.2.2 Service at 8,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 332
11.2.3 Service at 16,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 332
11.2.4 Service at 24,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 332
11.2.5 Service at 32,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 332
11.2.6 Service at 40,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 333
11.2.7 Service at 48,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 333
11.2.8 Service at 56,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 333
11.2.9 Service at 64,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 334
11.2.10 Service at 72,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 335
11.2.11 Service at 80,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 335
11.2.12 Service at 88,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 335
11.2.13 Service at 96,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 335
11.2.14 Service at 104,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 336
11.2.15 Service at 112,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 336
11.2.16 Service at 120,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 337
11.2.17 Service at 128,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 337
11.2.18 Service at 136,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 338
11.2.19 Service at 144,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 338
11.2.20 Service at 152,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 338
11.2.21 Service at 160,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 339
11.2.22 Service at 168,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 340
12 MY 2004 Maintenance Intervals........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 341
12.1 MY 2004 Maintenance Intervals - USA............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 341
12.1.1 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 341
12.1.2 Service at 5,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 342
12.1.3 Service at 10,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 342
12.1.4 Service at 15,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 342
12.1.5 Service at 20,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 342
12.1.6 Service at 25,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 343
12.1.7 Service at 30,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 343
12.1.8 Service at 35,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 343
12.1.9 Service at 40,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 343
12.1.10 Service at 45,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 344
12.1.11 Service at 50,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 344
12.1.12 Service at 55,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 345
12.1.13 Service at 60,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 345
12.1.14 Service at 65,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 346
12.1.15 Service at 70,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 346
12.1.16 Service at 75,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 346
12.1.17 Service at 80,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 346
12.1.18 Service at 85,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 347
12.1.19 Service at 90,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 347
12.1.20 Service at 95,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 348
12.1.21 Service at 100,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 348
12.1.22 Service at 105,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 348
12.2 MY 2004 Maintenance Intervals - Canada......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 349
12.2.1 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 349
12.2.2 Service at 8,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 350
12.2.3 Service at 16,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 350
12.2.4 Service at 24,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 350
12.2.5 Service at 32,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 350
12.2.6 Service at 40,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 351
12.2.7 Service at 48,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 351
12.2.8 Service at 56,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 351
12.2.9 Service at 64,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 351
12.2.10 Service at 72,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 352
12.2.11 Service at 80,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 352
12.2.12 Service at 88,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 353
12.2.13 Service at 96,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 353
12.2.14 Service at 104,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 353
12.2.15 Service at 112,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 353
12.2.16 Service at 120,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 354
12.2.17 Service at 128,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 354
12.2.18 Service at 136,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 355
12.2.19 Service at 144,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 355
12.2.20 Service at 152,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 355
12.2.21 Service at 160,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 355
12.2.22 Service at 168,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 356
13 MY 2003 Maintenance Intervals........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 357
13.1 MY 2003 Maintenance Intervals - USA............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 357
13.1.1 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 357
13.1.2 Service at 5,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 357
13.1.3 Service at 10,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 358
13.1.4 Service at 15,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 358
13.1.5 Service at 20,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 358
13.1.6 Service at 25,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 359
13.1.7 Service at 30,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 359
13.1.8 Service at 35,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 359
13.1.9 Service at 40,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 359
13.1.10 Service at 45,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 360
13.1.11 Service at 50,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 360
13.1.12 Service at 55,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 360
13.1.13 Service at 60,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 360
13.1.14 Service at 65,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 361
13.1.15 Service at 70,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 361
13.1.16 Service at 75,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 361
13.1.17 Service at 80,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 361
13.1.18 Service at 85,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 362
13.1.19 Service at 90,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 362
13.1.20 Service at 95,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 363
13.1.21 Service at 100,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 363
13.1.22 Service at 105,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 363
13.2 MY 2003 Maintenance Intervals - Canada......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 364
13.2.1 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 364
13.2.2 Service at 8,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 364
13.2.3 Service at 16,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 364
13.2.4 Service at 24,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 365
13.2.5 Service at 32,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 365
13.2.6 Service at 40,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 365
13.2.7 Service at 48,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 365
13.2.8 Service at 56,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 366
13.2.9 Service at 64,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 366
13.2.10 Service at 72,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 367
13.2.11 Service at 80,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 367
13.2.12 Service at 88,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 367
13.2.13 Service at 96,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 367
13.2.14 Service at 104,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 368
13.2.15 Service at 112,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 368
13.2.16 Service at 120,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 368
13.2.17 Service at 128,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 368
13.2.18 Service at 136,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 369
13.2.19 Service at 144,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 369
13.2.20 Service at 152,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 369
13.2.21 Service at 160,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 369
13.2.22 Service at 168,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 370
14 MY 2002 Maintenance Intervals........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 371
14.1 MY 2002 Maintenance Intervals - USA............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 371
14.1.1 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 371
14.1.2 Service at 5,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 371
14.1.3 Service at 10,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 372
14.1.4 Service at 15,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 372
14.1.5 Service at 20,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 372
14.1.6 Service at 25,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 373
14.1.7 Service at 30,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 373
14.1.8 Service at 35,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 373
14.1.9 Service at 40,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 373
14.1.10 Service at 45,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 374
14.1.11 Service at 50,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 374
14.1.12 Service at 55,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 374
14.1.13 Service at 60,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 374
14.1.14 Service at 65,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 375
14.1.15 Service at 70,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 375
14.1.16 Service at 75,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 375
14.1.17 Service at 80,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 375
14.1.18 Service at 85,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 376
14.1.19 Service at 90,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 376
14.1.20 Service at 95,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 377
14.1.21 Service at 100,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 377
14.1.22 Service at 105,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 377
14.2 MY 2002 Maintenance Intervals - Canada......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 378
14.2.1 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 378
14.2.2 Service at 8,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 378
14.2.3 Service at 16,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 378
14.2.4 Service at 24,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 379
14.2.5 Service at 32,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 379
14.2.6 Service at 40,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 379
14.2.7 Service at 48,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 379
14.2.8 Service at 56,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 380
14.2.9 Service at 64,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 380
14.2.10 Service at 72,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 381
14.2.11 Service at 80,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 381
14.2.12 Service at 88,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 381
14.2.13 Service at 96,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 381
14.2.14 Service at 104,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 382
14.2.15 Service at 112,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 382
14.2.16 Service at 120,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 382
14.2.17 Service at 128,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 382
14.2.18 Service at 136,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 383
14.2.19 Service at 144,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 383
14.2.20 Service at 152,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 383
14.2.21 Service at 160,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 383
14.2.22 Service at 168,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 384
15 MY 2001 Maintenance Intervals........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 385
15.1 MY 2001 Maintenance Intervals - USA............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 385
15.1.1 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 385
15.1.2 Service at 5,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 386
15.1.3 Service at 10,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 386
15.1.4 Service at 15,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 386
15.1.5 Service at 20,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 386
15.1.6 Service at 25,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 387
15.1.7 Service at 30,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 387
15.1.8 Service at 35,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 387
15.1.9 Service at 40,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 387
15.1.10 Service at 45,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 388
15.1.11 Service at 50,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 388
15.1.12 Service at 55,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 388
15.1.13 Service at 60,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 388
15.1.14 Service at 65,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 389
15.1.15 Service at 70,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 389
15.1.16 Service at 75,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 389
15.1.17 Service at 80,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 389
15.1.18 Service at 85,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 390
15.1.19 Service at 90,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 390
15.1.20 Service at 95,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 390
15.1.21 Service at 100,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 390
15.1.22 Service at 105,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 391
15.2 MY 2001 Maintenance Intervals - Canada......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 392
15.2.1 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 392
15.2.2 Service at 8,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 392
15.2.3 Service at 16,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 392
15.2.4 Service at 24,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 393
15.2.5 Service at 32,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 393
15.2.6 Service at 40,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 393
15.2.7 Service at 48,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 393
15.2.8 Service at 56,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 394
15.2.9 Service at 64,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 394
15.2.10 Service at 72,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 394
15.2.11 Service at 80,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 395
15.2.12 Service at 88,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 395
15.2.13 Service at 96,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 395
15.2.14 Service at 104,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 395
15.2.15 Service at 112,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 396
15.2.16 Service at 120,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 396
15.2.17 Service at 128,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 396
15.2.18 Service at 136,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 397
15.2.19 Service at 144,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 397
15.2.20 Service at 152,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 397
15.2.21 Service at 160,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 397
15.2.22 Service at 168,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 398
16 MY 2000 Maintenance Intervals........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 399
16.1 MY 2000 Maintenance Intervals - USA............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 399
16.1.1 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 399
16.1.2 Service at 5,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 399
16.1.3 Service at 10,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 400
16.1.4 Service at 15,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 400
16.1.5 Service at 20,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 400
16.1.6 Service at 25,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 401
16.1.7 Service at 30,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 401
16.1.8 Service at 35,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 401
16.1.9 Service at 40,000 miles.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 401
16.1.10 Service at 45,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 402
16.1.11 Service at 50,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 402
16.1.12 Service at 55,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 402
16.1.13 Service at 60,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 402
16.1.14 Service at 65,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 403
16.1.15 Service at 70,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 403
16.1.16 Service at 75,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 403
16.1.17 Service at 80,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 403
16.1.18 Service at 85,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 404
16.1.19 Service at 90,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 404
16.1.20 Service at 95,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 404
16.1.21 Service at 100,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 404
16.1.22 Service at 105,000 miles................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 405
16.2 MY 2000 Maintenance Intervals - Canada......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 406
16.2.1 Time-Dependent Maintenance Items......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 406
16.2.2 Service at 8,000 kilometers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 406
16.2.3 Service at 16,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 406
16.2.4 Service at 24,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 407
16.2.5 Service at 32,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 407
16.2.6 Service at 40,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 407
16.2.7 Service at 48,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 407
16.2.8 Service at 56,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 408
16.2.9 Service at 64,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 408
16.2.10 Service at 72,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 408
16.2.11 Service at 80,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 409
16.2.12 Service at 88,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 409
16.2.13 Service at 96,000 kilometers............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 409
16.2.14 Service at 104,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 409
16.2.15 Service at 112,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 410
16.2.16 Service at 120,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 410
16.2.17 Service at 128,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 410
16.2.18 Service at 136,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 411
16.2.19 Service at 144,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 411
16.2.20 Service at 152,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 411
16.2.21 Service at 160,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 411
16.2.22 Service at 168,000 kilometers........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 412
00-03 Maintenance Procedures.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 416
03 – Maintenance, Diagnosis................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 420
1 General Information................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 420
1.1 Engine Overview................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 420
1.2 Lifting Vehicle On a Hoist or Workshop Hoist.................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 422
1.2.1 Safety Precautions........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 422
1.2.2 Hoist and Jack Mounting Points............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 422
1.3 Labels.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 423
1.3.1 Your Next Service Label, Applying......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 423
1.4 Customer Maintenance Booklet Entries............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 424
1.5 Vehicle Diagnosis Tester........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 425
1.6 Vehicle Identification Number................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 427
1.6.2 VIN on Longitudinal Member Extension...................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 427
1.6.3 Meaning of Vehicle Identification Number (VIN)............................................................................................................................................................................................................................................................................................................................................................................................................................................................ 427
1.7 Vehicle Data Label.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 428
1.8 Severe Operating Conditions..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 428
1.9 Engine Code and Engine Number................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 429
1.10 Type Plate..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 429
1.11 Service Identification......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 429
1.12 Fixed Service.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 430
1.12.1 Fixed Service............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 430
1.12.2 Service Interval Display................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 431
1.13 Service Interval Display....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 433
1.14 Service Tables................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 435
1.15 Countries with High Air Dust Levels............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 436
1.16 Glossary....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 437
2 Golf Blue-e-motion Description ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 440
2.1 Label and Safety Precautions.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 440
2.1.1 High Voltage Warning Label................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 440
2.1.2 High Voltage Warning Label in the Engine Compartment...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 441
2.1.3 High Voltage Warning Label on the High Voltage Battery Underbody Box...................................................................................................................................................................................................................................................................................................................................................................................................................................... 441
2.1.4 High Voltage Warning Label on the High Voltage Battery Charge Box......................................................................................................................................................................................................................................................................................................................................................................................................................................... 442
2.2 Front Charge Socket, Checking Scan Functions.................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 442
2.3 Power Electronics, Removing and Installing...................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 442
2.4 Cellular Phone and Cellular Phone Preparation with Bluetooth® Coupling.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 443
2.4.1 Preparation Settings for Cellular phone................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 443
2.4.2 Operations in the Vehicle................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 443
2.5 Potential Equalization Cable, Checking.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 443
2.6 Radio Code, Checking with Vehicle Diagnostic Tester............................................................................................................................................................................................................................................................................................................................................................................................................................................................. 444
2.7 Service Interval Display, Coding for Delivery Inspection........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 444
2.8 Service Interval Display, Resetting............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 444
2.8.1 Service Interval Display, Resetting with Vehicle Diagnostic Tester........................................................................................................................................................................................................................................................................................................................................................................................................................................ 445
2.8.2 Service Interval Display, Resetting without Vehicle Diagnosis Tester...................................................................................................................................................................................................................................................................................................................................................................................................................................... 446
3 Maintenance Procedures................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 448
3.1 Removable Trailer Hitch, Check and Clean if Necessary........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 449
3.2 Ball Joint and Axle Bearing, Checking........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 452
3.3 Automatic Headlamp Control and Static Cornering Lamp, Checking Function......................................................................................................................................................................................................................................................................................................................................................................................................................................... 452
3.4 Automatic Transmission 09G, Changing ATF........................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 453
3.5 Battery Terminals, Checking for Secure Fit...................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 454
3.6 Battery, Checking with Battery Tester with Printer VAS 6161..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 456
3.7 Battery Level, Reading - Send Diagnostic Protocol Online........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 456
3.8 Tires, Checking Condition, Wear Pattern, Pressure and Tread Depth............................................................................................................................................................................................................................................................................................................................................................................................................................................... 457
3.8.1 General Information....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 457
3.8.2 Tires, Checking Condition................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 458
3.8.3 Tires, Checking Wear Pattern.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 458
3.9 Brake and Clutch System, Changing Brake Fluid................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 459
3.10 Brake System and Shock Absorbers, Checking for Leaks and Damage................................................................................................................................................................................................................................................................................................................................................................................................................................................ 463
3.11 Brake Pad Thickness and Front and Rear Brake Rotor Condition, Checking......................................................................................................................................................................................................................................................................................................................................................................................................................................... 464
3.11.1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 464
3.11.2 Front Disc Brake Pads.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 464
3.11.3 Rear Disc Brake Pads..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 465
3.11.4 Brake Rotors, Checking Condition......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 465
3.12 Brake Fluid Level, Checking.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 466
3.13 6-Speed DSG Transmission 02E, Changing Transmission Fluid and Filter........................................................................................................................................................................................................................................................................................................................................................................................................................................... 467
3.14 Diesel Particulate Filter, Checking............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 467
3.15 Power Window Regulators, Checking Position..................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 467
3.16 Hood Safety Catches, Lubricating............................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 468
3.17 Protective Joint Boots, Inspecting............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 469
3.18 Haldex Clutch, Changing Oil.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 469
3.19 Inner and Outer Body, Checking for Corrosion on Open Doors and Lids............................................................................................................................................................................................................................................................................................................................................................................................................................................ 472
3.20 Ribbed Belt, Checking Condition................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 472
3.21 Cooling System, Checking Freeze Protection and Coolant Level................................................................................................................................................................................................................................................................................................................................................................................................................................................... 473
3.21.1 Freeze Protection, Checking and Adding Coolant Additive.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 473
3.21.2 Coolant Level, Checking and Filling...................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 474
3.21.3 Mixture Ratio for R-Models............................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 475
3.21.4 Mixture Ratio............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 475
3.22 Diesel Fuel Filter, Removing and Installing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 475
3.23 Air Filter, Cleaning Housing and Removing and Installing Air Filter............................................................................................................................................................................................................................................................................................................................................................................................................................................ 479
3.23.1 2.5L SRE Engines......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 479
3.23.2 Diesel Engines, 2.0L TSI Engines......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 481
3.23.3 2.0L TSI engines......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 482
3.24 Engine and Engine Compartment Components, Checking for Leaks and Damage........................................................................................................................................................................................................................................................................................................................................................................................................................................ 484
3.25 Upper Engine Cover, Removing and Installing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 485
3.25.1 2.0L TFSI Engines........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 485
3.25.2 2.0L TFSI Engine, 173 kW, 188 kW and 199 kW.............................................................................................................................................................................................................................................................................................................................................................................................................................................................. 486
3.25.3 Air Filter Housing Stop Buffer, Replacing................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 488
3.25.4 2.5L SRE Engines......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 488
3.25.5 TDI Common Rail Engines.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 490
3.26 Lower Engine Compartment Cover, Removing and Installing........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 491
3.27 Engine Oil, Checking Level..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 491
3.28 Engine Oil, Draining or Extracting, Changing Oil Filter and Filling Oil........................................................................................................................................................................................................................................................................................................................................................................................................................................ 491
3.28.1 Engine Oil, Draining or Extracting....................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 491
3.28.2 Oil Filter, Replacing, 2.0L TFSI Engines (All Except 173 kW)............................................................................................................................................................................................................................................................................................................................................................................................................................................. 493
3.28.3 Oil Filter, Replacing, 2.0L TFSI Engine (173 kW) and 2.5L Gasoline Engines............................................................................................................................................................................................................................................................................................................................................................................................................................... 494
3.28.4 Oil Filter, Replacing, TDI Common Rail Engines........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 498
3.28.5 Engine Oil, Filling...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 499
3.29 Road Test...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 500
3.30 Wheel Bolts Tightening Specifications.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 500
3.31 Radio Code, Checking with Vehicle Diagnostic Tester............................................................................................................................................................................................................................................................................................................................................................................................................................................................ 504
3.32 Radio Navigation System, Entering Anti-Theft Code PIN and Storing Stations..................................................................................................................................................................................................................................................................................................................................................................................................................................... 504
3.33 Tire Pressure Monitoring System Display, Performing Basic Setting.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 505
3.34 Tire Repair Kit, Checking...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 507
3.35 Windshield Wiper and Washer System, Headlamp Washer System, Checking Functionality............................................................................................................................................................................................................................................................................................................................................................................................................................. 507
3.35.1 Fluid, Checking Freeze Protection and Filling............................................................................................................................................................................................................................................................................................................................................................................................................................................................ 507
3.35.2 Windshield Washer System, Checking and Adjusting Spray Nozzles........................................................................................................................................................................................................................................................................................................................................................................................................................................... 508
3.35.3 Headlamp Washer System, Checking Spray Nozzle Setting.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 510
3.35.4 Windshield Wiper Blades, Checking Park Position.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 511
3.36 Windshield Wiper Protectors, Removing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 511
3.36.1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 511
3.36.2 Version 1................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 512
3.36.3 Version 2................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 513
3.36.4 Version 3................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 513
3.37 Halogen Headlamps and Fog Lamps, Checking and Adjusting........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 514
3.37.1 Checking and Adjusting Requirements...................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 514
3.37.2 Headlamp Adjustment, Checking (with Test Screen without 15° Adjustment Line)............................................................................................................................................................................................................................................................................................................................................................................................................................. 515
3.37.3 Halogen Headlamps, Adjusting............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 516
3.37.4 Fog Lamps and Other Auxiliary Headlamps, Adjusting....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 517
3.38 Headlamps, Check the HID Headlamps and Adjust if Necessary..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 518
3.38.1 HID Headlamps,Test and Adjustment Requirements........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 518
3.38.2 HID Headlamps, Checking (with Test Screen without 15° Adjustment Line)................................................................................................................................................................................................................................................................................................................................................................................................................................... 519
3.38.3 HID Headlamps, Aiming.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 520
3.39 Sunroof Water Drains, Checking for Clearance and Cleaning If Necessary......................................................................................................................................................................................................................................................................................................................................................................................................................................... 521
3.40 Service Interval Display, Resetting............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 523
3.40.1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 523
3.40.2 Service Interval Display, Resetting with Vehicle Diagnostic Tester....................................................................................................................................................................................................................................................................................................................................................................................................................................... 523
3.40.3 Service Interval Display, Resetting without Vehicle Diagnosis Tester..................................................................................................................................................................................................................................................................................................................................................................................................................................... 524
3.41 Service Interval Display, Recoding............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 526
3.42 Sunroof, Checking Functionality, Cleaning and Lubricating Guide Rails.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 527
3.43 Tie Rod Ends, Checking Play, Security and Joint Boots.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 528
3.44 Dust and Pollen Filter, Cleaning Housing and Replacing Filter.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 528
3.45 Transport Mode, Switching Off.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 528
3.46 Transport Protection, Removing Locking Pieces from Front Axle Struts........................................................................................................................................................................................................................................................................................................................................................................................................................................... 529
3.47 Door Arrester, Lubricating..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 530
3.48 Clock and Date, Setting........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 530
3.49 Underbody Components, Checking for Damage...................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 531
3.50 Camshaft Drive Toothed Belt, Diesel, Removing and Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................... 531
3.51 Camshaft Drive Toothed Belt, 4-Cylinder Gasoline Engines without Change Interval, Checking..................................................................................................................................................................................................................................................................................................................................................................................................................... 532
3.52 Spark Plugs, Replacing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 532
3.52.1 For 2.0L TFSI Engines.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 532
3.52.2 For 2.5L SRE Engines..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 535
3.53 DTC Memories, Checking with Vehicle Diagnostic Tester and Correcting Faults According to Repair Procedure...................................................................................................................................................................................................................................................................................................................................................................................................... 537
4 Revision History...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 538
00-04 Maintenance............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 542
1 Engine Overview........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 546
1.1 Engine Overview..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 546
2 Service Work.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 548
2.1 Fixed Service....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 548
2.1.1 Service Identification........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 548
2.1.2 Fixed Service................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 548
2.1.3 Service Interval Display...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 549
2.2 Service Tables...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 551
3 General Information....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 553
3.1 Lifting Vehicle On a Hoist or Workshop Hoist........................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 553
3.1.1 Safety Precautions............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 553
3.1.2 Hoist and Jack Mounting Points................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 554
3.2 Labels.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 554
3.2.1 “Next Service” Label, Applying................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 554
3.3 Customer Maintenance Booklet Entries................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 555
3.4 Vehicle Diagnosis Tester............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 556
3.5 Vehicle Identification Number....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 557
3.5.2 VIN on Longitudinal Member Extension.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 558
3.5.3 Meaning of Vehicle Identification Number (VIN)................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 558
3.6 Vehicle Data Label.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 558
3.7 Severe Operating Conditions......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 559
3.8 Engine Code and Engine Number....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 559
3.9 Type Plate.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 559
4 Work Descriptions......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 562
4.1 Removable Trailer Hitch, Check and Clean if Necessary............................................................................................................................................................................................................................................................................................................................................................................................................................................................... 563
4.2 Ball Joint and Axle Bearing, Checking............................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 566
4.3 Automatic Headlamp Control and Static Cornering Lamp, Checking Function............................................................................................................................................................................................................................................................................................................................................................................................................................................. 566
4.4 Automatic Transmission 09G, Changing ATF............................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 567
4.5 Battery Terminals, Checking for Secure Fit.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 568
4.6 Battery, Checking with Battery Tester with Printer -VAS6161-........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 570
4.7 Tires, Checking Condition, Wear Pattern, Pressure and Tread Depth................................................................................................................................................................................................................................................................................................................................................................................................................................................... 571
4.7.1 General Information........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 571
4.7.2 Tires, Checking Condition..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 572
4.7.3 Tires, Checking Wear Pattern.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 572
4.8 Brake and Clutch System, Changing Brake Fluid....................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 573
4.9 Brake System and Shock Absorbers, Checking for Leaks and Damage..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 577
4.10 Brake Pad Thickness and Front and Rear Brake Rotor Condition, Checking............................................................................................................................................................................................................................................................................................................................................................................................................................................. 578
4.10.1 General Information.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 578
4.10.2 Front Disc Brake Pads........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 578
4.10.3 Rear Disc Brake Pads......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 579
4.10.4 Brake Rotors, Checking Condition............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 579
4.11 Brake Fluid Level, Checking........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 580
4.12 6-Speed DSG Transmission 02E, Changing Transmission Fluid and Filter............................................................................................................................................................................................................................................................................................................................................................................................................................................... 581
4.13 Diesel Particulate Filter, Checking................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 581
4.14 Power Window Regulators, Checking Position......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 581
4.15 Protective Joint Boots, Inspecting Visually........................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 582
4.16 Haldex Clutch, Changing Oil........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 583
4.17 Inner and Outer Body, Checking for Corrosion on Open Doors and Lids................................................................................................................................................................................................................................................................................................................................................................................................................................................ 587
4.18 Ribbed Belt, Checking Condition.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 587
4.19 Cooling System, Checking Freeze Protection and Coolant Level....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 588
4.19.1 General Information.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 588
4.19.2 Freeze Protection, Checking and Adding Coolant Additive...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 589
4.19.3 Coolant Level, Checking and Filling.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 591
4.19.4 Mixture Ratio for R-Models................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 591
4.19.5 Mixture Ratio................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 591
4.20 Diesel Fuel Filter, Replacing...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 592
4.21 Air Filter, Cleaning Housing and Removing and Installing Air Filter................................................................................................................................................................................................................................................................................................................................................................................................................................................ 595
4.21.1 2.5L SRE Engines............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 595
4.21.2 Diesel Engines, 2.0L TSI Engines............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 597
4.21.3 2.0L TSI engines............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 598
4.22 Engine and Engine Compartment Components, Checking for Leaks and Damage............................................................................................................................................................................................................................................................................................................................................................................................................................................ 600
4.23 Upper Engine Cover, Removing and Installing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 601
4.23.1 2.0L TFSI Engines............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 601
4.23.2 2.0L TFSI Engine, 173 kW, 188 kW and 199 kW.................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 602
4.23.3 Air Filter Housing Stop Buffer, Replacing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 604
4.23.4 2.5L SRE Engines............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 604
4.23.5 TDI Common Rail Engines...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 606
4.24 Lower Engine Compartment Cover, Removing and Installing............................................................................................................................................................................................................................................................................................................................................................................................................................................................ 607
4.25 Engine Oil, Checking Level......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 607
4.26 Engine Oil, Draining or Extracting, Changing Oil Filter and Filling Oil............................................................................................................................................................................................................................................................................................................................................................................................................................................ 607
4.26.1 Engine Oil, Draining or Extracting........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 607
4.26.2 Oil Filter, Replacing, 2.0L TFSI Engines (All Except 173 kW)................................................................................................................................................................................................................................................................................................................................................................................................................................................. 609
4.26.3 Oil Filter, Replacing, 2.0L TFSI Engine (173 kW) and 2.5L Gasoline Engines................................................................................................................................................................................................................................................................................................................................................................................................................................... 610
4.26.4 Oil Filter, Replacing, TDI Common Rail Engines............................................................................................................................................................................................................................................................................................................................................................................................................................................................... 614
4.26.5 Engine Oil, Filling.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 615
4.27 Engine Oil, Capacities and Specifications.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 615
4.27.1 Golf......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 615
4.27.2 Golf Plus.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 616
4.28 Road Test.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 616
4.29 Wheel Bolts Tightening Specifications.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 616
4.30 Radio Code, Checking with Vehicle Diagnostic Tester................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 620
4.31 Radio Navigation System, Entering Anti-Theft Code PIN and Storing Stations......................................................................................................................................................................................................................................................................................................................................................................................................................................... 620
4.32 Tire Pressure Monitoring System Display, Performing Basic Setting.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 621
4.33 Tire Repair Kit, Checking.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 622
4.34 Windshield Wiper and Washer System, Headlamp Washer System, Checking Functionality................................................................................................................................................................................................................................................................................................................................................................................................................................. 623
4.34.1 Fluid, Checking Freeze Protection and Filling................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 623
4.34.2 Windshield Washer System, Checking and Adjusting Spray Nozzles............................................................................................................................................................................................................................................................................................................................................................................................................................................... 624
4.34.3 Headlamp Washer System, Checking Spray Nozzle Setting........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 626
4.34.4 Windshield Wiper Blades, Checking the Park Position.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 627
4.34.5 Rear Wiper Blade, Checking the Park Position................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 627
4.35 Windshield Wiper Protectors, Removing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 627
4.35.1 General Information.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 627
4.35.2 Version 1.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 628
4.35.3 Version 2.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 629
4.35.4 Version 3.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 630
4.36 Halogen Headlamps and Fog Lamps, Checking and Adjusting if Necessary............................................................................................................................................................................................................................................................................................................................................................................................................................................... 630
4.36.1 Testing and Adjustment Requirements.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 630
4.36.2 Headlamp Adjustment, Checking with Test Screen without 15° Adjustment Line................................................................................................................................................................................................................................................................................................................................................................................................................................... 632
4.36.3 Halogen Headlamps, Adjusting................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 633
4.36.4 Fog Lamps and Other Auxiliary Headlamps, Adjusting........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 633
4.37 HID Headlamp Adjustment, Checking and Adjusting If Necessary....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 634
4.37.1 Testing and Adjustment Requirements.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 634
4.37.2 Headlamp Adjustment, Checking with Test Screen without 15° Adjustment Line................................................................................................................................................................................................................................................................................................................................................................................................................................... 635
4.37.3 HID Headlamps, Adjusting..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 637
4.38 Sunroof Water Drains, Checking for Clearance and Cleaning If Necessary............................................................................................................................................................................................................................................................................................................................................................................................................................................. 637
4.39 Service Interval Display, Resetting................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 639
4.39.1 Service Interval Display, Resetting with Vehicle Diagnostic Tester........................................................................................................................................................................................................................................................................................................................................................................................................................................... 640
4.39.2 Service Interval Display, Resetting without Vehicle Diagnosis Tester......................................................................................................................................................................................................................................................................................................................................................................................................................................... 641
4.40 Service Interval Display, Coding................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 643
4.41 Sunroof, Checking Functionality, Cleaning and Lubricating Guide Rails.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 644
4.42 Tie Rod Ends, Checking Play, Security and Joint Boots.............................................................................................................................................................................................................................................................................................................................................................................................................................................................. 644
4.43 Dust and Pollen Filter, Cleaning Housing and Replacing Filter...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 644
4.44 Transport Mode, Switching Off...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 645
4.45 Transport Protection, Removing Locking Pieces from Front Axle Struts............................................................................................................................................................................................................................................................................................................................................................................................................................................... 646
4.46 Door Arrester, Lubricating......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 647
4.47 Clock and Date, Setting............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 647
4.48 Underbody Components, Checking for Damage.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 648
4.49 Camshaft Drive Toothed Belt, Diesel, Removing and Installing....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 648
4.50 Camshaft Drive Toothed Belt, 4-Cylinder Gasoline Engines without Change Interval, Checking......................................................................................................................................................................................................................................................................................................................................................................................................................... 649
4.51 Spark Plugs, Replacing............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 649
4.51.1 For 2.0L TFSI Engines........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 649
4.51.2 For 2.5L SRE Engines......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 652
4.52 Diagnostic Trouble Code (DTC) Memories, Checking with Vehicle Diagnostic Tester and Correcting Faults According to Repair Procedure................................................................................................................................................................................................................................................................................................................................................................................ 654
4.53 Driving School Pedals, Lubricating................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 654
4.53.1 Driving School Pedals, Lubricating, Automatic Transmission................................................................................................................................................................................................................................................................................................................................................................................................................................................... 655
4.53.2 Driving School Pedals, Lubricating, Manual Transmission...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 657
5 Golf Blue-E-Motion Description ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 660
5.1 Label and Safety Precautions........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 660
5.1.1 High Voltage Warning Label.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 660
5.1.2 High Voltage Warning Label in the Engine Compartment.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 661
5.1.3 High Voltage Warning Label on the High Voltage Battery Underbody Box.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 661
5.1.4 High Voltage Warning Label on the High Voltage Battery Charge Box............................................................................................................................................................................................................................................................................................................................................................................................................................................. 662
5.2 Front Charge Socket, Checking Scan Functions........................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 662
5.3 Power Electronics, Removing and Installing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 662
5.4 Cellular Phone and Cellular Phone Preparation with Bluetooth® Coupling.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 663
5.4.1 Preparation Settings for Cellular phone....................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 663
5.4.2 Operations in the Vehicle..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 663
5.5 Potential Equalization Cable, Checking.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 663
5.6 Radio Code, Checking with Vehicle Diagnostic Tester................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 664
5.7 Service Interval Display, Coding for Delivery Inspection............................................................................................................................................................................................................................................................................................................................................................................................................................................................ 664
5.8 Service Interval Display, Resetting................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 665
5.8.1 Service Interval Display, Resetting with Vehicle Diagnostic Tester............................................................................................................................................................................................................................................................................................................................................................................................................................................ 665
5.8.2 Service Interval Display, Resetting without Vehicle Diagnosis Tester.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 666
6 Glossary.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 667
6.1 Glossary............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 667
00-05 Maintenance Procedures.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 672
03 – Maintenance, Diagnosis................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 676
1 Note.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 676
2 Revision History...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 677
00-06 Towing Guide.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 681
00 – General, Technical Data................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 687
1 Foreword.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 687
1.1 Legal Requirements outside Germany.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 687
2 Technical Requirements................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 688
2.1 Factory-Installed Trailer Hitch................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 688
2.2 Retrofitted Trailer Hitch....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 688
2.3 Ball Head....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 688
2.4 Trailer Socket.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 688
2.4.1 »7-Pin« Trailer Socket.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 689
2.4.2 »13-Pin« Trailer Socket................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 689
2.5 Towing Recognition Control Module -J345-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 689
2.5.1 Towing Recognition Control Module -J345-, Retrofitting.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 690
2.5.2 Towing Recognition Control Module -J345-, Coding.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 690
2.6 Engine Cooling.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 690
2.7 Exterior Rearview Mirror........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 691
2.8 Reinforced Shock Absorbers and Coil Springs..................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 691
3 Operating and Driving Tips............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 692
4 General Information................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 693
4.1 Trailer Hitch Type Label........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 693
4.2 Combined Weight................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 693
4.3 Trip Recorder................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 693
5 Tongue Weight Specifications.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 694
6 Legal Requirements.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 695
7 Beetle from MY 2012................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 696
8 Bora from MY 1999 and Bora Wagon from MY 1999......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 697
9 Eos from MY 2006...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 699
10 Fox from MY 2004..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 700
11 Golf from MY 1992 and Golf Wagon from MY 1994........................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 701
12 Golf Cabrio from MY 1994............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 703
13 Golf from MY 1998 and Golf Wagon from MY 1999........................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 704
13.1 Golf R32....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 705
13.2 Jubilee GTI.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 705
13.3 Golf Bifuel.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 706
14 Golf from MY 2004.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 707
15 Golf Plus from MY 2005............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 709
16 Golf Wagon from MY 2007.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 711
17 Golf from MY 2009.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 712
18 Golf Plus from MY 09................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 714
19 CrossGolf from MY 2009............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 716
20 Golf Wagon from MY 10................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 717
21 Golf Convertible from MY 2012........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 718
22 Golf from MY 13...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 719
23 Golf Wagon from MY 2014.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 722
24 e-Golf from MY 2014.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 724
25 Golf Sportsvan from MY 2015.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 725
26 Jetta from MY 2005................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 727
27 Jetta from MY 11..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 729
28 Jetta from 2015...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 731
29 Lupo 3L, Lupo FSI and Lupo GTI from MY 1999.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 733
30 Lupo from MY 1999.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 734
31 New Beetle from MY 1999.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 735
32 New Beetle RSi....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 737
33 New Beetle Convertible from MY 2003.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 738
34 Passat Sedan and Wagon from MY 1994.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 739
34.1 Passat Syncro.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 740
34.1.1 Increasing Towing Weight................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 741
35 Passat Sedan and Wagon from MY 97.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 742
36 Passat Sedan and Wagon from MY 2001.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 743
37 Passat W8 from MY 2002............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 744
38 Passat Sedan from MY 2006............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 745
39 Passat Wagon from MY 2006............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 747
40 Passat CC from MY 2009; CC from MY 2010; CC from MY 2012............................................................................................................................................................................................................................................................................................................................................................................................................................................................. 749
41 Passat Sedan from MY 11.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 752
42 Passat Wagon from MY 2011 and Passat Alltrack from MY 2012........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 754
43 Passat Sedan, From MY 2015........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 756
44 Passat Wagon, From MY 2015........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 758
45 Phaeton from MY 2003................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 760
46 Polo from MY 1995.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 761
47 Polo Classic from MY 1996............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 762
48 Polo Wagon from MY 1998.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 763
49 Polo from MY 02...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 764
50 Polo Fun from MY 2004................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 766
50.1 Trailer Hitch, Retrofitting.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 766
51 Polo Sedan from MY 2004.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 767
52 Polo from MY 10...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 768
53 Cross Polo from MY 2010.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 770
54 Polo from MY 2014.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 771
55 CrossPolo from MY 2014............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 773
56 Scirocco from MY 2009................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 774
57 Scirocco from MY 2015................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 775
58 Sharan from MY 1996.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 776
58.1 Retrofitting Trailer Hitch in Sharan BlueMotion................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 777
59 Sharan from MY 2011.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 778
60 Tiguan from MY 2008.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 779
60.1 Tiguan Trend & Fun/Sport & Style............................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 779
60.2 Tiguan Track & Field........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 780
61 Touran from MY 2003.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 783
62 CrossTouran.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 785
63 Touareg from MY 2003................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 786
64 Touareg from MY 10................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 787
65 up! from MY 2012..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 788
66 e-up! from MY 2014................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 789
67 Vento from MY 1992................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 790
68 Revision History..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 791
01-Engine Mechanical & Systems.pdf (p.795-1373)..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 795
00 – General, Technical Data.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 803
1 Engine Number............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 803
2 Engine Specifications..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 804
10 – Engine Assembly............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 805
1 Engine, Removing and Installing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 805
1.1 Engine, Removing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 805
1.2 Transmission and Engine, Disconnecting and Assembling............................................................................................................................................................................................................................................................................................................................................................................................................................................................... 816
1.3 Engine, Securing on Assembly Stand.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 818
1.4 Engine, Installing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 818
2 Subframe Mount............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 821
2.1 Overview - Subframe Mount, Golf, Eos, Passat, and CC................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 821
2.2 Overview - Subframe Mount, Tiguan................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 823
2.3 Subframe Mount, Checking Adjustment................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 824
2.4 Subframe Mount, Adjusting, Passat from MY 2006 and CC............................................................................................................................................................................................................................................................................................................................................................................................................................................................... 824
2.5 Subframe Mount, Adjusting, Rabbit, and Eos.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 827
2.6 Subframe Mount, Adjusting, Tiguan................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 830
3 Special Tools............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 835
13 – Crankshaft, Cylinder Block................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 842
1 Cylinder Block, Belt Pulley Side.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 842
1.1 Overview - Ribbed Belt Drive........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 842
1.2 Ribbed Belt, Removing and Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 844
1.3 Ribbed Belt Tensioning Damper, Removing and Installing, Passat from MY 2006 and CC.................................................................................................................................................................................................................................................................................................................................................................................................................................. 845
1.4 Ribbed Belt Tensioner, Removing and Installing, Rabbit and Eos...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 848
1.5 Ribbed Belt Tensioner, Removing and Installing, Tiguan.............................................................................................................................................................................................................................................................................................................................................................................................................................................................. 850
1.6 Sub-Assembly Bracket, Removing and Installing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 854
1.7 Vibration Damper, Removing and Installing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 856
1.8 Vibration Damper Shaft Seal, Always Replace......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 861
2 Cylinder Block on Transmission Side....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 864
2.1 Overview - Transmission Side Sealing Flange and Dual Mass Flywheel/Drive Plate...................................................................................................................................................................................................................................................................................................................................................................................................................................... 864
2.2 Dual Mass Flywheel, Removing and Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 865
2.3 Drive Plate, Removing and Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 866
2.4 Transmission-Side Sealing Flange, Removing and Installing........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 868
3 Crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 871
3.1 Overview - Crankshaft............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 871
3.2 Sensor Wheel, Removing and Installing............................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 873
3.3 Crankshaft Bearing Shells, Allocating............................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 873
3.4 Needle Bearings, Removing from Crankshaft and Installing............................................................................................................................................................................................................................................................................................................................................................................................................................................................ 874
3.5 Crankshaft Dimensions............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 876
3.6 Crankshaft, Measuring Axial Clearance............................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 876
3.7 Crankshaft, Measuring Radial Clearance.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 877
4 Piston and Connecting Rod................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 878
4.1 Overview - Piston and Connecting Rod................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 878
4.2 Pistons, Removing and Installing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 879
4.3 Pistons and Cylinder Bore, Checking................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 881
4.4 New Connecting Rod, Disconnecting................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 882
5 Special Tools............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 883
15 – Cylinder Head, Valvetrain.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 890
1 Chain Drive............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 890
1.1 Overview - Timing Chain Covers...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 890
1.2 Camshaft Adjustment Valve 1 -N205-, Removing and Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 893
1.3 Upper Timing Chain Cover, Removing and Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 893
1.4 Lower Timing Chain Cover, Removing and Installing, Passat and CC.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 895
1.5 Lower Timing Chain Cover, Removing and Installing, Rabbit and Eos................................................................................................................................................................................................................................................................................................................................................................................................................................................... 900
1.6 Lower Timing Chain Cover, Removing and Installing, Tiguan........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 905
1.7 Overview - Camshaft Timing Chain.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 911
1.8 Camshaft Timing Chain, Removing and Installing...................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 913
1.9 Overview - Balance Shaft Drive Chain................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 925
1.10 Balance Shaft Drive Chain, Removing and Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 927
1.11 Balance Shaft Intake Side, Removing and Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 927
1.12 Exhaust Side Balance Shaft, Removing and Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 930
1.13 Valve Timing, Checking............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 932
2 Cylinder Head............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 934
2.1 Overview - Cylinder Head............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 934
2.2 Engine Cover, Removing and Installing............................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 937
2.3 Cylinder Head, Removing and Installing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 938
2.3.1 General Information........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 938
2.3.2 Cylinder Head, Removing and Installing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 939
2.3.3 Cylinder Head and Camshaft Timing Chain, Removing and Installing.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 960
2.4 Compression, Checking............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 970
2.5 Vacuum Pump, Removing and Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 971
3 Valvetrain................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 973
3.1 Overview - Valvetrain............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 973
3.2 Camshaft, Removing and Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 975
3.3 Camshafts, Checking Axial Play...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 990
3.4 Valve Stem Seals, Always replace.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 990
3.5 Valve Guides, Checking.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 993
4 Special Tools............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 995
17 – Lubrication................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1005
1 Oil Pan and Oil Pump......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1005
1.1 Overview - Oil Pan and Oil Pump.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1005
1.2 Oil Separator, Removing and Installing..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1008
1.3 Oil Pan Lower Section, Removing and Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................1009
1.4 Oil Pump, Removing and Installing...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1011
1.5 Oil Pan Upper Section, Removing and Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................1013
1.6 Oil Pressure Regulation Valve -N428-, Removing and Installing, Engine Codes CCZA, CCZB, CCZC, CCZD, CDAA, and CDAB..................................................................................................................................................................................................................................................................................................................................................................................................1016
2 Engine Oil................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1018
3 Oil Filter, Engine Oil Cooler and Oil Pressure Switch, Engine Codes.......................................................................................................................................................................................................................................................................................................................................................................................................................................................1019
3.1 Overview - Oil Filter, Engine Oil Cooler and Oil Pressure Switch -F1-...............................................................................................................................................................................................................................................................................................................................................................................................................................................1019
3.2 Engine Oil Cooler, Removing and Installing..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1020
3.3 Oil Pressure and Oil Pressure Switch, Checking......................................................................................................................................................................................................................................................................................................................................................................................................................................................................1021
4 Oil Filter, Oil Cooler and Oil Pressure Switch, Engine Codes CCZA, CCZB, CCZC, CCZD, CDAA, and CDAB.......................................................................................................................................................................................................................................................................................................................................................................................................................1023
4.1 Overview - Oil Filter and Oil Cooler................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1023
4.2 Engine Oil Cooler, Removing and Installing..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1024
4.3 Oil Pressure Switch -F1-, Removing and Installing...................................................................................................................................................................................................................................................................................................................................................................................................................................................................1025
4.4 Reduced Oil Pressure Switch -F378-, Removing and Installing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................1026
4.5 Oil Pressure and Oil Pressure Switch, Checking......................................................................................................................................................................................................................................................................................................................................................................................................................................................................1027
5 Special Tools.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1031
19 – Cooling System.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1033
1 Cooling System............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1033
1.1 Coolant Hose Connection Diagram.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1033
1.2 Coolant, Draining and Filling.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1035
1.3 Coolant System, Checking for Leaks..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1040
2 Coolant Pump, Coolant Thermostat and Coolant Pipes........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1042
2.1 Overview - Coolant Pump and Coolant Thermostat......................................................................................................................................................................................................................................................................................................................................................................................................................................................................1042
2.2 Coolant Pump, Removing and Installing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1044
2.3 Coolant Pump Toothed Belt, Removing and Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................1046
2.4 Coolant Pump Drive Shaft Seal, Always replace.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................1047
2.5 Coolant Thermostat, Removing and Installing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1048
2.6 Engine Coolant Temperature Sensor -G62-, Removing and Installing....................................................................................................................................................................................................................................................................................................................................................................................................................................................1051
2.7 Overview - Coolant Pipes............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1054
2.8 Front Coolant Pipes, Removing and Installing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1055
2.9 Small Coolant Pipe, Removing and Installing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1058
2.10 Overview - After-Run Coolant Pump -V51-............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1059
2.11 After-Run Coolant Pump -V51-, Removing and Installing..............................................................................................................................................................................................................................................................................................................................................................................................................................................................1060
3 Radiator and Radiator Fan.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1062
3.1 Overview - Radiator, Fan Shroud and Radiator Fan, Passat, CC, Golf, and Eos.........................................................................................................................................................................................................................................................................................................................................................................................................................................1062
3.2 Radiator Identification Sensor -G611-, Installing...................................................................................................................................................................................................................................................................................................................................................................................................................................................................1063
3.3 Overview - Radiator, Fan Shroud and Radiator Fan, Tiguan............................................................................................................................................................................................................................................................................................................................................................................................................................................................1064
3.4 Fan Shroud, Removing and Installing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1065
3.5 Radiator Fan -V7- and Radiator Fan 2 -V177-, Removing and Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................1067
3.6 Radiator, Passat, CC, Golf, and Eos, Removing and Installing........................................................................................................................................................................................................................................................................................................................................................................................................................................................1067
3.7 Radiator, Removing and Installing, Tiguan...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1068
4 Special Tools.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1071
20 – Fuel Supply................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1074
1 Safety Precautions........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1074
1.1 Safety Precautions when Working on Fuel Supply System...............................................................................................................................................................................................................................................................................................................................................................................................................................................................1074
2 Guidelines for Clean Working Conditions...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1076
3 Fuel Tank, Passat and CC..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1077
3.1 Overview - Fuel Tank, Engine Codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA and CDAB.................................................................................................................................................................................................................................................................................................................................................................................................................................1077
3.2 Overview - Fuel Tank, Engine Codes..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1078
3.3 Fuel Tank, Draining.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1079
3.3.1 General Information...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1079
3.3.2 Fuel Tank, Draining with Fuel Pump Installed..................................................................................................................................................................................................................................................................................................................................................................................................................................................................1080
3.3.3 Fuel Tank, Draining When More than 3/4 Full...................................................................................................................................................................................................................................................................................................................................................................................................................................................................1081
3.3.4 Fuel Tank, Draining When Less Than 3/4 Full...................................................................................................................................................................................................................................................................................................................................................................................................................................................................1082
3.4 Fuel Tank, Removing and Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1083
3.4.1 General Information...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1083
3.4.2 Fuel Tank, Removing...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1083
3.4.3 Fuel Tank, Installing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1085
4 Fuel Tank, Rabbit.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1087
4.1 Overview - Fuel Tank, Engine Codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB and CDAA.......................................................................................................................................................................................................................................................................................................................................................................................................................................1087
4.2 Overview - Fuel Tank, Engine Codes..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1089
4.3 Fuel Tank, Draining, Engine Codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB and CDAA........................................................................................................................................................................................................................................................................................................................................................................................................................................1091
4.3.1 General Information...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1091
4.3.2 Fuel Tank, Draining with Fuel Pump Installed..................................................................................................................................................................................................................................................................................................................................................................................................................................................................1092
4.3.3 Fuel Tank, Draining When More than 3/4 Full...................................................................................................................................................................................................................................................................................................................................................................................................................................................................1093
4.3.4 Fuel Tank, Draining When Less Than 3/4 Full...................................................................................................................................................................................................................................................................................................................................................................................................................................................................1094
4.4 Fuel Tank, Draining, Engine Codes...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1095
4.5 Fuel Tank, Removing and Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1096
5 Fuel Tank, Tiguan.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1099
5.1 Overview - Fuel Tank................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1099
5.2 Fuel Tank, Draining.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1101
5.2.1 General Information...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1101
5.2.2 Fuel Tank, Draining with Fuel Pump Installed..................................................................................................................................................................................................................................................................................................................................................................................................................................................................1101
5.2.3 Fuel Tank, Draining When More than 3/4 Full...................................................................................................................................................................................................................................................................................................................................................................................................................................................................1103
5.2.4 Fuel Tank, Draining When Less Than 3/4 Full...................................................................................................................................................................................................................................................................................................................................................................................................................................................................1104
5.3 Fuel Tank, Removing and Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1105
6 Fuel Tank, Eos............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1109
6.1 Overview - Fuel Tank, Engine Codes CAWA, CAWB, CCZA and CCZB........................................................................................................................................................................................................................................................................................................................................................................................................................................................1109
6.2 Overview - Fuel Tank, Engine Codes CBFA, CCTA.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................1111
6.3 Fuel Tank, Draining.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1113
6.3.1 General Information...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1113
6.3.2 Fuel Tank, Draining with Fuel Pump Installed..................................................................................................................................................................................................................................................................................................................................................................................................................................................................1114
6.3.3 Fuel Tank, Draining When More than 3/4 Full...................................................................................................................................................................................................................................................................................................................................................................................................................................................................1115
6.3.4 Fuel Tank, Draining When Less Than 3/4 Full...................................................................................................................................................................................................................................................................................................................................................................................................................................................................1116
6.4 Fuel Tank, Removing and Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1117
6.4.1 Removing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1117
6.4.2 Fuel Tank, Installing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1119
7 Fuel Supply, Servicing, Passat and CC.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1121
7.1 Fuel Delivery Unit, Removing and Installing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1121
7.2 Fuel Level Sensor -G-, Removing and Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................1124
7.3 Fuel Pump, Checking.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1126
7.3.1 General Information...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1126
7.3.2 Function and Power Supply, Checking...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1126
7.3.3 Fuel Pressure, Checking.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1129
7.3.4 Fuel Pressure, Checking while Driving, Engine Codes CCZA, CCZB, CDAA and CDAB.................................................................................................................................................................................................................................................................................................................................................................................................................................1131
7.3.5 Residual Pressure, Checking...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1132
7.3.6 Fuel Delivery Rate, Checking, Engine Codes....................................................................................................................................................................................................................................................................................................................................................................................................................................................................1133
7.3.7 Fuel Delivery Rate, Checking, Engine Codes CCZA, CCZB, CDAA and CDAB..........................................................................................................................................................................................................................................................................................................................................................................................................................................1136
7.3.8 Current Draw, Checking........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1138
8 Fuel Supply System, Servicing, Golf and Eos...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1140
8.1 Fuel Delivery Unit, Removing and Installing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1140
8.2 Fuel Level Sensor -G-, Removing and Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................1143
8.3 Transfer Fuel Pump -G6-, Checking...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1144
8.3.1 General Information and Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1144
8.3.2 Function and Power Supply, Checking...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1144
8.3.3 Fuel Pressure, Checking.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1147
8.3.4 Fuel Pressure, Checking while Driving, Engine Codes CCZA, CCZB, CDAA and CDAB.................................................................................................................................................................................................................................................................................................................................................................................................................................1149
8.3.5 Residual Pressure, Checking...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1151
8.3.6 Fuel Delivery Rate, Checking, Engine Codes....................................................................................................................................................................................................................................................................................................................................................................................................................................................................1153
8.3.7 Fuel Delivery Rate, Checking, Engine Codes CCZA, CCZB, CDAA and CDAB..........................................................................................................................................................................................................................................................................................................................................................................................................................................1157
8.3.8 Current Draw, Checking........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1159
8.3.9 Low Side Fuel Pressures.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1160
9 Fuel Supply, Servicing, Tiguan............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1162
9.1 Fuel Delivery Unit, Removing and Installing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1162
9.2 Fuel Level Sensor G, Removing and Installing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1164
9.3 Suction Jet Pump, Fuel Filter and Pressure Relief Valve, Removing and Installing....................................................................................................................................................................................................................................................................................................................................................................................................................................1165
9.4 Fuel Level Sensor 2 -G169-, Removing and Installing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................1167
9.5 Fuel Pump Control Module -J538-, Removing and Installing............................................................................................................................................................................................................................................................................................................................................................................................................................................................1168
9.6 Fuel Pump, Checking.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1169
9.6.1 General Information and Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1169
9.6.2 Function and Power Supply, Checking...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1170
9.6.3 Fuel Pressure, Checking.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1172
9.6.4 Fuel Pressure, Checking while Driving, Engine Codes CCZA, CCZB, CCZC and CCZD.................................................................................................................................................................................................................................................................................................................................................................................................................................1173
9.6.5 Residual Pressure, Checking...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1175
9.6.6 Fuel Delivery Rate, Checking. Engine Codes CCTA...............................................................................................................................................................................................................................................................................................................................................................................................................................................................1176
9.6.7 Fuel Delivery Rate, Checking, Engine Codes CCZA, CCZB, CCZC, CCZD.............................................................................................................................................................................................................................................................................................................................................................................................................................................1179
9.6.8 Current Draw, Checking........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1181
10 Electronic Engine Output Control (EPC)...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1183
10.1 Overview - Accelerator Pedal Module................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1183
10.2 Accelerator Pedal Module, Removing and Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................1183
11 EVAP Canister System, Passat, CC and Tiguan..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1186
11.1 Overview - EVAP Canister System, Engine Codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CCZC, CCZD, CDAA, and CDAB........................................................................................................................................................................................................................................................................................................................................................................................................1186
11.2 Overview - EVAP Canister System....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1188
11.2.1 General Information..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1188
11.2.2 Overview - EVAP System.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1188
11.2.3 Overview - EVAP Canister System, Vehicles with Additional Filter.............................................................................................................................................................................................................................................................................................................................................................................................................................................1190
11.3 Fuel Tank Ventilation, Checking, Engine Codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CCZC, CCZD, CDAA, and CDAB........................................................................................................................................................................................................................................................................................................................................................................................................1190
11.4 Fuel System, Checking for Leaks....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1192
11.4.1 Fuel System, Checking for Leaks..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1192
11.4.2 Fuel System Leak Detection...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1196
11.4.3 EVAP System, Function Overview...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1197
11.4.4 Leak Detection Pump -V144-, Checking Vacuum Supply...........................................................................................................................................................................................................................................................................................................................................................................................................................................................1198
12 EVAP Canister System, Golf, Eos and Scirocco with Engine Codes CAWA, CAWB, BZB, CGYA, CCZA, CCZB and CDAA................................................................................................................................................................................................................................................................................................................................................................................................................1200
12.1 Overview - EVAP System.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1200
12.2 Fuel Tank, Checking Ventilation....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1201
13 EVAP System, Rabbit and Eos..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1203
13.1 Overview Plan - EVAP System........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1203
13.2 Overview - EVAP System, Golf.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1205
13.3 Overview - EVAP System, Eos........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1206
13.4 EVAP Canister, Removing and Installing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1207
13.5 Leak Detection Pump -V144-, Removing and Installing, Golf..........................................................................................................................................................................................................................................................................................................................................................................................................................................................1208
13.6 Leak Detection Pump -V144-, Removing and Installing, Eos...........................................................................................................................................................................................................................................................................................................................................................................................................................................................1209
13.7 Fuel System, Checking for Leaks....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1209
13.7.1 Fuel System, Checking for Leaks..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1209
13.7.2 Fuel System Leak Detection...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1213
13.7.3 EVAP System, Function Overview...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1214
13.7.4 Leak Detection Pump -V144-, Checking Vacuum Supply...........................................................................................................................................................................................................................................................................................................................................................................................................................................................1215
14 Special Tools............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1217
21 – Turbocharger, Supercharger.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1221
1 Turbocharger..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1221
1.1 Overview - Turbocharger.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1221
1.1.1 General Information...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1221
1.1.2 Part I, Engine Codes BZB, CGYA, CDAA and CDAB.................................................................................................................................................................................................................................................................................................................................................................................................................................................................1223
1.1.3 Part I........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1224
1.1.4 Part II.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1225
1.1.5 Part III......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1226
1.1.6 Part IV.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1227
1.1.7 Turbocharger Recirculation Valve -N249- Installation Position.................................................................................................................................................................................................................................................................................................................................................................................................................................................1228
1.2 Hose Connections with Connector Couplings, Assembling...............................................................................................................................................................................................................................................................................................................................................................................................................................................................1228
1.3 Turbocharger, Removing and Installing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1229
1.4 Turbocharger Vacuum Diaphragm, Checking.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1235
1.5 Turbocharger Vacuum Diaphragm, Adjusting, Engine Codes BZB, CGYA, CDAA and CDAB.....................................................................................................................................................................................................................................................................................................................................................................................................................................1236
1.6 Turbocharger Vacuum Diaphragm, Removing and Installing..............................................................................................................................................................................................................................................................................................................................................................................................................................................................1240
2 Charge Air System.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1241
2.1 Overview - Charge Air Cooling System, Passat, CC, Tiguan and Eos....................................................................................................................................................................................................................................................................................................................................................................................................................................................1241
2.2 Overview - Charge Air Cooling System, Golf..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1242
2.3 Overview - Noise Generator, Golf....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1244
2.4 Structure-Borne Sound Actuator -R214- and Structure Borne Sound Control Module -J869-...............................................................................................................................................................................................................................................................................................................................................................................................................................1245
2.4.1 General Information...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1245
2.4.2 Overview - Structure-Borne Sound Actuator -R214- and Structure-Borne Sound Control Module -J869-..............................................................................................................................................................................................................................................................................................................................................................................................................1245
2.4.3 Overview - Structure-Borne Sound Actuator -R214- and Structure-Borne Sound Control Module -J869-, RHD.........................................................................................................................................................................................................................................................................................................................................................................................................1247
2.5 Overview - Turbocharging System.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1248
2.6 Charge Air Cooler, Removing and Installing, Golf and Eos............................................................................................................................................................................................................................................................................................................................................................................................................................................................1248
2.7 Charge Air Cooler, Removing and Installing, Passat, and CC..........................................................................................................................................................................................................................................................................................................................................................................................................................................................1250
2.8 Charge Air Cooler, Removing and Installing, Tiguan..................................................................................................................................................................................................................................................................................................................................................................................................................................................................1251
2.9 Charge Air Guide to Noise Generator, Removing and Installing Rabbit.................................................................................................................................................................................................................................................................................................................................................................................................................................................1252
2.10 Charge Air System, Checking for Leaks..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1253
3 Special Tools.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1256
24 – Multiport Fuel Injection...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1259
1 Safety Precautions and Clean Working Conditions...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1259
1.1 OBD General Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1259
2 Injection System..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1260
2.1 Technical Data......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1260
2.2 Overview - Component Locations......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1260
2.3 Overview - Air Filter...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1265
2.4 Air Filter Housing, Removing and Installing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1267
2.5 Air Filter Element, Removing and Installing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1267
2.6 Mass Airflow Sensor -G70-, Removing and Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................1268
2.7 Overview - Intake Manifold..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1269
2.8 Overview - Fuel Rail................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1272
2.9 Intake Manifold with Fuel Rail......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1273
2.9.1 Intake Manifold with Fuel Rail, Removing and Installing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................1273
2.9.2 Fuel Rail, Separating from Intake Manifold....................................................................................................................................................................................................................................................................................................................................................................................................................................................................1279
2.10 Fuel Injectors, Removing and Installing............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1280
2.11 Fuel Injector Teflon® Seal, Always replace.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1283
2.12 Fuel Injectors, Cleaning...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1284
2.13 Fuel Pressure Sensor -G247-, Removing and Installing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................1285
2.14 Throttle Valve Control Module -J338-, Removing and Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................................1286
2.15 Throttle Valve Control Module -J338-, Cleaning.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................1288
2.16 Overview - High Pressure Pump with Fuel Pressure Regulator Valve -N276-............................................................................................................................................................................................................................................................................................................................................................................................................................................1288
2.17 High Pressure Pump, Removing and Installing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1289
3 Components, Checking......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1292
3.1 Fuel Pressure Sensor -G247-, Checking...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1292
3.2 Variable Intake Manifold, Checking..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1294
4 Engine Control Module -J623-, Passat and CC through 11/2010..............................................................................................................................................................................................................................................................................................................................................................................................................................................................1297
4.1 Engine Control Module, Removing and Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................1297
4.2 Engine Control Module with Protective Housing, Removing and Installing..............................................................................................................................................................................................................................................................................................................................................................................................................................................1298
5 Engine Control Module -J623-, Golf and Eos through 11/2008...............................................................................................................................................................................................................................................................................................................................................................................................................................................................1301
5.1 Engine Control Module, Removing and Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................1301
5.2 Engine Control Module with Protective Housing, Removing and Installing..............................................................................................................................................................................................................................................................................................................................................................................................................................................1301
6 Engine Control Module -J623-, Golf and Eos from 11/2008, CC from 11/2010.................................................................................................................................................................................................................................................................................................................................................................................................................................................1304
6.1 Engine Control Module, Removing and Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................1304
6.2 Engine Control Module with Protective Housing, Removing and Installing..............................................................................................................................................................................................................................................................................................................................................................................................................................................1305
7 Engine Control Module -J623-, Tiguan.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1309
7.1 Engine Control Module, Removing and Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................1309
7.2 Engine Control Module with Protective Housing, Removing and Installing..............................................................................................................................................................................................................................................................................................................................................................................................................................................1310
8 Engine Control Module -J623-, Scirocco through 11/2008...................................................................................................................................................................................................................................................................................................................................................................................................................................................................1313
8.1 Engine Control Module, Removing and Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................1313
8.2 Engine Control Module with Protective Housing, Removing and Installing..............................................................................................................................................................................................................................................................................................................................................................................................................................................1314
9 Special Tools.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1317
26 – Exhaust System, Emission Controls..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1320
1 Exhaust System, Passat and CC.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1320
1.1 Overview - Exhaust System, Engine Codes BZB, CAWA, CAWB and CGYA....................................................................................................................................................................................................................................................................................................................................................................................................................................................1320
1.2 Overview - Exhaust System, Engine Code CCTA.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1323
1.3 Overview - Exhaust System, Engine Code CBFA.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1325
1.4 Center Muffler and Rear Muffler, Separating.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1327
1.5 Exhaust System, Installing without Tension..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1328
1.6 Clamping Sleeve, Installation Position and Tightening Specification.................................................................................................................................................................................................................................................................................................................................................................................................................................................1329
1.7 Catalytic Converters with Front Exhaust Pipe, Removing and Installing...............................................................................................................................................................................................................................................................................................................................................................................................................................................1330
1.8 Exhaust System, Checking for Leaks..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1332
2 Exhaust System, Rabbit, and Eos...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1333
2.1 Overview - Exhaust System, Engine Code CAWB.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1333
2.2 Overview - Exhaust System, Golf from MY 2004, and Eos, Engine Codes CCTA............................................................................................................................................................................................................................................................................................................................................................................................................................................1335
2.3 Overview - Exhaust System, Engine Code CBFA.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1337
2.4 Overview - Exhaust System, Golf from MY 2009, Engine Codes CCZA and CCZB............................................................................................................................................................................................................................................................................................................................................................................................................................................1340
2.5 Overview - Exhaust System, Golf from MY 2009, Engine Codes CCTA.....................................................................................................................................................................................................................................................................................................................................................................................................................................................1342
2.6 Center Muffler and Rear Muffler, Separating.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1344
2.7 Exhaust System, Installing without Tension..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1345
2.8 Clamping Sleeve, Installation Position and Tightening Specification.................................................................................................................................................................................................................................................................................................................................................................................................................................................1346
2.9 Catalytic Converters with Front Exhaust Pipe, Removing and Installing...............................................................................................................................................................................................................................................................................................................................................................................................................................................1347
2.10 Exhaust System, Checking for Leaks.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1349
3 Exhaust System, Tiguan....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1350
3.1 Overview - Exhaust System, Engine Codes CCTA........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1350
3.2 Overview - Exhaust System, Engine Code CAWA and CAWB................................................................................................................................................................................................................................................................................................................................................................................................................................................................1352
3.3 Center Muffler and Rear Muffler, Separating.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1354
3.4 Exhaust System, Installing without Tension..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1355
3.5 Catalytic Converters with Front Exhaust Pipe, Removing and Installing...............................................................................................................................................................................................................................................................................................................................................................................................................................................1356
3.6 Clamping Sleeve, Installation Position and Tightening Specification.................................................................................................................................................................................................................................................................................................................................................................................................................................................1360
3.7 Exhaust System, Checking for Leaks..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1361
4 Secondary Air Injection System, Engine Code CBFA..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1362
4.1 Overview - Secondary Air Injection System...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1362
4.2 Secondary Air Injection Pump Motor -V101-, Removing and Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................1362
4.3 Secondary Air Injection Solenoid Valve -N112-, Removing and Installing..............................................................................................................................................................................................................................................................................................................................................................................................................................................1363
5 Special Tools.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1365
28 – Ignition/Glow Plug System..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1366
1 Ignition System, Servicing................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1366
1.1 Ignition System General Information.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1366
1.2 Safety Precautions..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1366
1.3 Overview - Ignition System..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1367
1.4 Ignition Coils with Power Output Stages, Removing and Installing....................................................................................................................................................................................................................................................................................................................................................................................................................................................1368
1.5 Knock Sensor 1 -G61-, Removing and Installing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................1369
1.6 Engine Speed Sensor -G28-, Removing and Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................1369
1.7 Test Data and Spark Plugs...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1370
2 Special Tools.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1371
3 Revision History..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1372
02-Engine Performance.pdf (p.1374-1801).............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1374
02-00 2.0L TDI Common Rail CBEA-CJAA............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1374
02-01 Generic Scan Tool.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1384
ST – Generic Scan Tool......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1388
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1388
1.1 Safety Precautions..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1389
1.2 Clean Working Conditions........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1391
1.3 On Board Diagnostic Systems.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1391
1.4 Malfunction Indicator Lamp Illumination.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1391
1.5 Controller Area Network Data Link...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1391
1.6 Electronic Power Control Warning Lamp...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1392
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1393
2.1 Fuel Supply System..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1393
2.2 Evaporative Emission System.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1393
2.3 Electronic Engine Power Control.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1394
2.4 Fuel Injection System...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1394
2.5 Engine Control Module...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1394
2.6 Exhaust System Components.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1395
2.7 Secondary Air Injection System..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1395
2.8 Ignition System.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1395
2.9 Automatic Transmission..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1395
3 Diagnosis and Testing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1396
3.1 Preliminary Check...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1396
3.2 Readiness Code..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1396
3.3 Diagnostic Modes 01 - 0A........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1398
3.3.1 Diagnostic Mode 01 - Read Current System Data.............................................................................................................................................................................................................................................................................................................................................................................................................................................................1399
3.3.2 Diagnostic Mode 02 - Read Operating Conditions............................................................................................................................................................................................................................................................................................................................................................................................................................................................1400
3.3.3 Diagnostic Mode 03 - Read DTC Memory......................................................................................................................................................................................................................................................................................................................................................................................................................................................................1402
3.3.4 Diagnostic Mode 04 - Erase DTC Memory.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................1403
3.3.5 Diagnostic Mode 05 - Read Oxygen Sensor Monitoring Test Results...........................................................................................................................................................................................................................................................................................................................................................................................................................................1404
3.3.6 Diagnostic Mode 06 - Read Test Results for Specific Diagnostic Functions..................................................................................................................................................................................................................................................................................................................................................................................................................................1404
3.3.7 Diagnostic Mode 07 - Read Faults Detected During the Current or Last Driving Cycle........................................................................................................................................................................................................................................................................................................................................................................................................................1415
3.3.8 Diagnostic Mode 08 - Request Control of On-Board System, Test or Component................................................................................................................................................................................................................................................................................................................................................................................................................................1415
3.3.9 Diagnostic Mode 09 - Read Vehicle Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................1416
3.3.10 Diagnostic Mode 0A - Check Permanent DTC Memory..........................................................................................................................................................................................................................................................................................................................................................................................................................................................1417
3.4 Engine DTC Tables...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1418
3.4.1 Engine Control Module.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1418
3.5 Transmission DTC Tables.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1493
3.5.1 DSG Transmission Mechatronic, DSG 6spd 02E................................................................................................................................................................................................................................................................................................................................................................................................................................................................1493
3.6 Diagnostic Procedures...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1522
3.6.1 Camshaft Adjustment Valve 1 - N205-, Checking.............................................................................................................................................................................................................................................................................................................................................................................................................................................................1523
3.6.2 Camshaft Position Sensor -G40-, Checking..................................................................................................................................................................................................................................................................................................................................................................................................................................................................1525
3.6.3 Speedometer -G21-, Checking...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1527
3.6.4 CAN Bus Terminal Resistance, Checking.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................1528
3.6.5 LIN-Bus Circuit, Checking.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1530
3.6.6 Catalytic Converter, Checking.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1533
3.6.7 Turbocharger, G-Charger...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1533
3.6.8 Charge Air Pressure Sensor - G31-, Checking...............................................................................................................................................................................................................................................................................................................................................................................................................................................................1534
3.6.9 Turbocharger Recirculating Valve - N249-, Checking........................................................................................................................................................................................................................................................................................................................................................................................................................................................1536
3.6.10 Wastegate Bypass Regulator Valve -N75-, Checking.........................................................................................................................................................................................................................................................................................................................................................................................................................................................1538
3.6.11 Engine Coolant Temperature Sensor - G62-, Checking.......................................................................................................................................................................................................................................................................................................................................................................................................................................................1540
3.6.12 Engine Coolant Temperature Sensor On Radiator Outlet -G83-, Checking.....................................................................................................................................................................................................................................................................................................................................................................................................................................1544
3.6.13 Engine Speed Sensor - G28-, Checking.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................1546
3.6.14 EVAP canister purge regulator valve 1 - N80-, Checking...................................................................................................................................................................................................................................................................................................................................................................................................................................................1549
3.6.15 Evaporative System, Checking for Leaks...................................................................................................................................................................................................................................................................................................................................................................................................................................................................1551
3.6.16 Fuel Injectors, Checking.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1552
3.6.17 Fuel Pressure Sensor - G247-, Checking...................................................................................................................................................................................................................................................................................................................................................................................................................................................................1555
3.6.18 Fuel Pressure Regulator Valve - N276-, Checking..........................................................................................................................................................................................................................................................................................................................................................................................................................................................1557
3.6.19 LIN-Bus Circuit, Checking................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1559
3.6.20 Fuel Pump Delivery Quantity, Checking....................................................................................................................................................................................................................................................................................................................................................................................................................................................................1561
3.6.21 Fuel Pressure Test.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1562
3.6.22 Fuel Pump Electrical, Testing............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1564
3.6.23 Ignition Coil with Power Output Stage, Checking..........................................................................................................................................................................................................................................................................................................................................................................................................................................................1565
3.6.24 Outside Air Temperature Sensor - G17-, Checking..........................................................................................................................................................................................................................................................................................................................................................................................................................................................1568
3.6.25 Intake Air Temperature Sensor -G42-, Checking............................................................................................................................................................................................................................................................................................................................................................................................................................................................1570
3.6.26 Intake Manifold Runner Position Sensor - G336-, Checking.................................................................................................................................................................................................................................................................................................................................................................................................................................................1574
3.6.27 Intake Manifold Runner Control Valve -N316-, Checking....................................................................................................................................................................................................................................................................................................................................................................................................................................................1576
3.6.28 Knock Sensor 1 - G61-, Checking..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1578
3.6.29 Leak Detection Pump - V144-, Checking....................................................................................................................................................................................................................................................................................................................................................................................................................................................................1579
3.6.30 Mass Air Flow Sensor - G70-, Checking....................................................................................................................................................................................................................................................................................................................................................................................................................................................................1582
3.6.31 Heated Oxygen Sensor -G39-, Checking.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................1584
3.6.32 Oxygen Sensor Heater -Z19-, Checking.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................1586
3.6.33 Heated Oxygen Sensor 2 -G108-, Checking..................................................................................................................................................................................................................................................................................................................................................................................................................................................................1588
3.6.34 Oxygen Sensor 2 Heater -Z28-, Checking...................................................................................................................................................................................................................................................................................................................................................................................................................................................................1591
3.6.35 Oxygen Sensor After Three Way Catalytic Converter -G130-, Checking.......................................................................................................................................................................................................................................................................................................................................................................................................................................1593
3.6.36 Heater For Oxygen Sensor 1 After Catalytic Converter -Z29-, Checking.....................................................................................................................................................................................................................................................................................................................................................................................................................................1596
3.6.37 Secondary Air Injection Pump Relay - J299 -, Checking....................................................................................................................................................................................................................................................................................................................................................................................................................................................1598
3.6.38 Secondary Air Injection Combination Valve, Checking......................................................................................................................................................................................................................................................................................................................................................................................................................................................1602
3.6.39 TCM to ECM CAN Bus Terminal Resistance, Checking.........................................................................................................................................................................................................................................................................................................................................................................................................................................................1603
3.6.40 Accelerator Pedal Position Sensor -G79- / Accelerator Pedal Position Sensor 2 -G185-, Checking...........................................................................................................................................................................................................................................................................................................................................................................................................1605
3.6.41 Throttle Valve Control Module - J338-, Checking..........................................................................................................................................................................................................................................................................................................................................................................................................................................................1607
3.6.42 Voltage Supply, Checking.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1611
3.6.43 Electrical Components for Regulating Transmission 02E....................................................................................................................................................................................................................................................................................................................................................................................................................................................1614
3.6.44 Safety Precautions.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1614
3.6.45 Selector Lever Voltage Supply, Checking..................................................................................................................................................................................................................................................................................................................................................................................................................................................................1615
3.6.46 Voltage Supply of Direct Shift Gearbox Mechatronic, Checking.............................................................................................................................................................................................................................................................................................................................................................................................................................................1616
02-02A 1998-2012 DTC List.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1622
P Codes.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1622
U Codes.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1680
02-02B Volkswagen Engine & transmission Fault Codes.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1686
02-03 VW New OBD II drive cycle procedure.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1710
02-04A Immobilizer Self Study Program...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1713
02-04B VW Revised Immobilizer Service Program for independent Workshops.........................................................................................................................................................................................................................................................................................................................................................................................................................................................1768
02-05A Volkswagen 2007-2013 Revised CAL IDs and CVN_Data........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1769
02-05B 2014-2011 VW ECM calibration IDs and CVNs................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1777
02-05C VW Q1 2015 CAL IDs and CVNs..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1781
02-05D 2011-2014 VW Revised Calibration IDs and CVN Data........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1786
VW Group Q2_2013............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1786
02-05E 2015 VW Cal IDS and CVNs.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1791
03-Manual Transmission & Rear Final Drive.pdf (p.1802-2705).........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1802
03-01 Manual Transmission.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1802
00 – General, Technical Data................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1808
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1808
1.1 Calculating Transmission Ratio “i”..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1808
1.2 General Repair Information......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1808
1.3 Safety Precautions, Vehicles with Start/Stop System.............................................................................................................................................................................................................................................................................................................................................................................................................................................................1811
1.4 Transmission Identification.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1811
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1813
2.1 Overview - Powertrain...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1813
3 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1815
3.1 Code Letters, Transmission Allocation, Ratios and Capacities, Golf from MY 2004.................................................................................................................................................................................................................................................................................................................................................................................................................................1815
3.2 Code Letters, Transmission Allocation, Ratios and Capacities, Golf from MY 2009.................................................................................................................................................................................................................................................................................................................................................................................................................................1818
3.3 Engine Codes, Transmission Allocation, Ratios and Capacities, Golf Plus from MY 2005............................................................................................................................................................................................................................................................................................................................................................................................................................1819
3.4 Engine Codes, Transmission Allocation, Ratios and Capacities, Golf Plus from MY 2009............................................................................................................................................................................................................................................................................................................................................................................................................................1820
3.5 Engine Codes, Transmission Allocations, Ratios and Capacities, Passat from MY 2006..............................................................................................................................................................................................................................................................................................................................................................................................................................1820
30 – Clutch.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1823
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1823
1.1 Clutch System, Bleeding.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1823
1.2 Determining Clutch Manufacturer, 1.9L 66 kW Turbo Diesel and 1.9L 77 kW Turbo Diesel............................................................................................................................................................................................................................................................................................................................................................................................................................1823
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1826
2.1 Clutch Mechanism Overview.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1826
2.2 Overview - Pedal Assembly.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1828
2.3 Overview - Hydraulics...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1830
2.4 Overview - Clutch Release Mechanism.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1832
2.5 Overview - “Sachs” Clutch.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1833
2.6 Clutch Assembly Overview, “LuK”.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1834
2.7 Clutch Assembly Overview, with Single Flywheel..................................................................................................................................................................................................................................................................................................................................................................................................................................................................1835
2.8 Hydraulics Assembly Overview, RHD...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1837
3 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1839
3.1 Over-Center Spring..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1839
3.1.1 Over-Center Spring, Golf from MY 2004.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................1839
3.1.2 Over-Center Spring, Golf from MY 2009.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................1843
3.1.3 Over-center Spring, Removing and Installing, Golf from 2009 RHD...........................................................................................................................................................................................................................................................................................................................................................................................................................................1847
3.1.4 Over-Center Spring, Golf Plus.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1851
3.1.5 Over-Center Spring,Passat.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1855
3.2 Clutch Pedal....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1856
3.2.1 Clutch Pedal,Golf from MY 2004, Golf from MY 2009 and Golf Plus...........................................................................................................................................................................................................................................................................................................................................................................................................................................1856
3.2.2 Clutch Pedal,Passat.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1857
3.3 Mounting Bracket................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1859
3.3.1 Mounting Bracket,Golf from MY 2004........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1859
3.3.2 Bracket,Golf from MY 2009.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1863
3.3.4 Mounting Bracket, Golf Plus...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1873
3.3.5 Mounting Bracket, Passat..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1878
3.4 Clutch Master Cylinder..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1880
3.5 Clutch Position Sensor -G476-...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1882
3.6 Slave Cylinder..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1884
3.7 Clutch Release Mechanism, Servicing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1886
3.8 “Sachs” Clutch..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1887
3.9 “LuK” Clutch....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1890
3.10 Clutch, With Single Flywheel...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1892
4 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1894
34 – Controls, Housing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1897
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1897
1.1 Transmission Fluid, Checking and Filling........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1897
1.1.1 Preparing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1897
1.1.2 Transmission Fluid, Draining..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1898
1.1.3 Transmission Fluid, Filling...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1899
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1900
2.1 Shift Mechanism Installation Position...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................1900
2.2 Overview - Gearshift Mechanism..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1902
2.3 Overview - Gearshift Knob and Cover.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................1902
2.4 Overview - Gearshift Lever and Gearshift Housing, through 10/2006...............................................................................................................................................................................................................................................................................................................................................................................................................................................1904
2.5 Overview - Gearshift Lever and Gearshift Housing, from 11/2006..................................................................................................................................................................................................................................................................................................................................................................................................................................................1906
2.6 Operating Cables Assembly Overview, Cable Bracket and Metal Relay Lever.........................................................................................................................................................................................................................................................................................................................................................................................................................................1908
2.7 Operating Cables Assembly Overview, Cable Bracket and Plastic Relay Lever.......................................................................................................................................................................................................................................................................................................................................................................................................................................1911
2.8 Selector Mechanism, Adjusting...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1913
2.8.1 Function..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1915
2.9 Overview - Subframe Mount.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1916
2.10 Transmission Overview..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1918
2.11 Overview - Transmission Disassembling and Assembling...........................................................................................................................................................................................................................................................................................................................................................................................................................................................1919
2.12 Overview - Transmission Housing Cover and 5th Gear, Removing and Installing....................................................................................................................................................................................................................................................................................................................................................................................................................................1920
2.13 Overview - Transmission Housing and Gearshift Mechanism, Removing and Installing...............................................................................................................................................................................................................................................................................................................................................................................................................................1922
2.14 Transmission Housing and Clutch Housing Assembly Overview......................................................................................................................................................................................................................................................................................................................................................................................................................................................1923
2.15 Overview - Shift Unit..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1926
2.16 Overview - Shift Forks.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1927
2.17 Input Shaft, Output Shafts, Differential and Shift Forks.......................................................................................................................................................................................................................................................................................................................................................................................................................................................1928
3 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1930
3.1 Shift Knob with Boot and Noise Insulation, Golf.................................................................................................................................................................................................................................................................................................................................................................................................................................................................1930
3.2 Gearshift Knob with Boot and Noise Insulation, Golf Plus........................................................................................................................................................................................................................................................................................................................................................................................................................................................1931
3.3 Boot with Shifter Knob and Noise Insulation, Passat.............................................................................................................................................................................................................................................................................................................................................................................................................................................................1932
3.4 Plastic Relay Lever.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1934
3.5 Selector Mechanism..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1936
3.6 Transmission, Golf from MY 2004.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1940
3.6.1 Transmission, Removing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1941
3.6.2 Transmission, Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1946
3.6.3 Tightening Specifications.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1952
3.7 Transmission, Golf from MY 2009, with Turbo Diesel..............................................................................................................................................................................................................................................................................................................................................................................................................................................................1953
3.7.1 Transmission, Removing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1954
3.7.2 Transmission, Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1960
3.7.3 Tightening Specifications.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1967
3.8 Transmission, Golf from MY 2009, Gasoline Engine................................................................................................................................................................................................................................................................................................................................................................................................................................................................1968
3.8.1 Transmission, Removing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1969
3.8.2 Transmission, Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1976
3.8.3 Tightening Specifications.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1983
3.9 Transmission, Golf Plus.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1984
3.9.1 Transmission, Removing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1985
3.9.2 Transmission, Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1992
3.9.3 Tightening Specifications.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1999
3.10 Transmission, Passat...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2000
3.10.1 Transmission, Removing...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2000
3.10.2 Transmission, Installing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2005
3.10.3 Tightening Specifications................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2012
3.11 Transmission, Transporting.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2012
3.12 Assembly Sequence, Transmission Housing Cover and 5th Gear.....................................................................................................................................................................................................................................................................................................................................................................................................................................................2013
3.12.1 Removing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2014
3.12.2 Installing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2017
3.13 Transmission Housing and Clutch Housing, Servicing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................2017
3.14 Shift Unit, Servicing..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2020
3.15 Shift Forks, Servicing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2021
4 Disassembly and Assembly..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2023
4.1 Gearshift Mechanism, from 11/2006...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2023
4.1.1 Base Plate, Installing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2026
4.2 Transmission, Assembly Sequence.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2027
4.2.1 Removing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2027
4.2.2 Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2033
5 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2040
35 – Gears, Shafts..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2058
1 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2058
1.1 Overview - Input Shaft..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2058
1.2 Input Shaft, Adjusting..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2060
1.3 Overview - Output Shaft.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2064
1.4 Output Shaft, Adjusting.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2068
1.5 Overview - Reverse Shaft........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2071
2 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2072
2.1 Input Shaft Seal, Replacing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2072
3 Disassembly and Assembly..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2073
3.1 Input Shaft.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2073
3.2 Output Shaft....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2078
3.3 Reverse Shaft...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2086
4 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2088
39 – Final Drive, Differential..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2096
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2096
1.1 Differentiating Right Flange Shaft Seals........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2096
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2097
2.1 Adjustment Overview.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2097
2.2 Overview - Differential.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2097
2.3 Differential, Adjusting.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2100
3 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2102
3.1 Flange Shaft Seal, Left, With Installed Manual Transmission.....................................................................................................................................................................................................................................................................................................................................................................................................................................................2102
3.1.1 Removing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2102
3.1.2 Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2103
3.1.3 Tightening Specification..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2103
3.2 Seal, Right, With Installed Manual Transmission, Two-Part for Flange Shaft and Sleeve...........................................................................................................................................................................................................................................................................................................................................................................................................................2103
3.2.1 Removing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2103
3.2.2 Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2105
3.2.3 Tightening Specification..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2105
3.3 Seal and Sleeve, One-Piece Right Flange Shaft Seal and Sleeve, With Installed Manual Transmission...............................................................................................................................................................................................................................................................................................................................................................................................................2105
3.3.1 Removing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2106
3.3.2 Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2106
3.3.3 Tightening Specification..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2107
4 Disassembly and Assembly..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2108
4.1 Differential....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2108
5 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2112
6 Revision History......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2118
03-02 Manual Transmission (BPY,CCT,CBF,CJAA)....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2122
00 – General, Technical Data................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2128
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2128
1.1 Transmission Identification.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2128
1.2 Calculating Transmission Ratio I................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2128
1.3 General Repair Information......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2129
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2133
2.1 Powertrain Overview.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2133
3 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2135
3.1 Code Letters, Allocation and Capacities.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2135
3.2 Code Letters, Allocation and Capacities.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2136
3.3 Code Letters, Allocation and Capacities.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2136
3.4 Code Letters, Allocation and Capacities.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2137
3.5 Code Letters, Allocation and Capacities.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2138
30 – Clutch.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2139
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2139
1.1 Clutch System, Bleeding.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2139
1.2 Determining the Clutch Manufacturer.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2139
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2142
2.1 Clutch Pedal Overview...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2142
2.2 Hydraulic System Overview.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2145
2.3 Clutch Release Mechanism Overview...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2147
2.4 Clutch Overview, Sachs..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2149
2.5 Clutch Overview, LuK............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2151
3 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2152
3.1 Fastener Tightening Specifications..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2152
4 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2153
4.1 Over-Center Spring..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2153
4.2 Over-Center Spring..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2157
4.3 Clutch Pedal....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2160
4.4 Mounting Bracket................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2161
4.5 Mounting Bracket................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2166
4.6 Over-Center Spring..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2170
4.7 Clutch Pedal....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2171
4.8 Mounting Bracket................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2173
4.9 Mounting Bracket................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2175
4.10 Clutch Master Cylinder.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2178
4.11 Clutch Position Sensor -G476-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2180
4.12 Breather Assembly..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2182
4.13 Slave Cylinder with Release Bearing............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2182
4.14 Clutch Hydraulic Hose/Line.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2183
4.15 Clutch, Sachs..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2185
4.16 Clutch, LuK....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2188
5 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2192
34 – Controls, Housing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2194
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2194
1.1 Transmission Fluid, Checking....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2194
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2196
2.1 Shift Mechanism Overview, Installed Position....................................................................................................................................................................................................................................................................................................................................................................................................................................................................2196
2.2 Shift Knob, Boot and Noise Insulation Overview..................................................................................................................................................................................................................................................................................................................................................................................................................................................................2198
2.3 Shift Lever and Housing Overview, through 10/2006...............................................................................................................................................................................................................................................................................................................................................................................................................................................................2200
2.4 Shift Lever and Housing Overview, from 11/2006..................................................................................................................................................................................................................................................................................................................................................................................................................................................................2202
2.5 Shift and Selector Cables Overview..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2204
2.6 Shift Mechanism, Adjusting......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2208
2.6.1 Function..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2211
2.7 Transmission Gear Overview......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2211
2.8 Transmission Gear Overview......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2213
2.9 Transmission Housing and Gear Shift Unit Overview...............................................................................................................................................................................................................................................................................................................................................................................................................................................................2214
2.10 Input Shaft, Output Shafts, Differential and Selector Rods Overview............................................................................................................................................................................................................................................................................................................................................................................................................................................2216
2.11 Input Shaft, Output Shafts, Differential and Selector Rods Overview............................................................................................................................................................................................................................................................................................................................................................................................................................................2218
2.12 Selector Shafts and Forks, Installed Position..................................................................................................................................................................................................................................................................................................................................................................................................................................................................2220
2.13 Gear Shift Unit................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2220
3 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2223
3.1 Fastener Tightening Specifications..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2223
3.1.1 Tightening Specifications.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2224
3.1.2 Tightening Specifications.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2225
3.1.3 Tightening Specifications.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2226
3.1.4 Tightening Specifications.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2227
3.1.5 Tightening Specifications.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2228
3.1.6 Tightening Specifications.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2229
4 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2231
4.1 Shift Knob, Boot and Noise Insulation...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2231
4.2 Shift Knob, Boot and Noise Insulation...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2233
4.3 Shift Mechanism.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2234
4.4 Plastic Relay Lever.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2239
4.5 Selector Shaft Seal.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2241
4.6 Transmission, Transporting......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2242
4.7 Securing, to the Engine and Transmission Holder.................................................................................................................................................................................................................................................................................................................................................................................................................................................................2243
4.8 Transmission, Removing..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2243
4.9 Transmission, Installing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2251
4.10 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2256
4.11 Transmission, Installing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2265
4.12 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2272
4.13 Transmission, Installing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2281
4.14 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2288
4.15 Transmission, Installing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2296
4.16 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2301
4.17 Transmission, Installing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2311
4.18 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2318
4.19 Transmission, Installing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2327
5 Disassembly and Assembly..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2333
5.1 Determining Sealing Cap Type....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2333
5.2 Selector Mechanism..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2333
5.3 Transmission, without a Sealing Cap Lock Ring...................................................................................................................................................................................................................................................................................................................................................................................................................................................................2338
5.4 Transmission, with a Sealing Cap Lock Ring......................................................................................................................................................................................................................................................................................................................................................................................................................................................................2348
5.5 Transmission Housing............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2358
5.6 Clutch Housing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2366
5.7 Selector Forks..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2369
6 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2372
7 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2380
8 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2388
9 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2396
10 Special Tools........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2403
11 Special Tools........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2411
35 – Gears, Shafts..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2419
1 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2419
1.1 Input Shaft Overview............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2419
1.2 Output Shaft, 1st to 4th Gears Overview.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2420
1.3 Output Shaft, 1st to 4th Gears, Adjusting.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................2424
1.3.1 Shim, Selecting...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2425
1.3.2 Adjustment Shim Table.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2426
1.3.3 Checking the Measurement..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2426
1.4 5th, 6th and Reverse Gear Output Shaft Overview.................................................................................................................................................................................................................................................................................................................................................................................................................................................................2427
1.5 Output Shaft, 5th, 6th and Reverse Gears, Adjusting.............................................................................................................................................................................................................................................................................................................................................................................................................................................................2429
1.5.1 Shim, Selecting...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2430
1.5.2 Adjustment Shim Table.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2431
1.5.3 Checking the Measurement..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2431
2 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2433
2.1 Input Shaft Seal................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2433
3 Disassembly and Assembly..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2434
3.1 Input Shaft.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2434
3.1.1 Grooved Ball Bearing Changes..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2437
3.2 Output Shaft, 1st to 4th Gears..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2439
3.3 Output Shaft, 5th, 6th and Reverse Gears........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2458
4 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2464
39 – Final Drive, Differential..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2469
1 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2469
1.1 Adjustment Overview.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2469
1.2 Differential, Adjusting.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2469
1.2.1 Shim, Selecting...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2470
2 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2472
2.1 Fastener Tightening Specifications..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2472
3 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2473
3.1 Left Flange Shaft and Seal......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2473
3.2 Right Flange Shaft and Seal.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2474
4 Disassembly and Assembly..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2477
4.1 Differential....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2477
5 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2483
6 Revision History......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2486
03-03 Rear Final Drive..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2490
00 – General, Technical Data................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2496
1 Rear Final Drive Identification.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2496
2 Codes, Assembly Allocation, Capacities, Golf from MY 2004.............................................................................................................................................................................................................................................................................................................................................................................................................................................................2497
3 Codes, Assembly Allocation, Capacities, Passat from MY 2006...........................................................................................................................................................................................................................................................................................................................................................................................................................................................2499
3.1 Rear Final Drive 02D/0AV, Passat................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2499
3.2 Rear Final Drive 01Z, Passat....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2500
3.3 Rear Final Drive 0BS, Passat....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2500
4 Codes, Assembly Allocation, Capacities, Tiguan from MY 2008...........................................................................................................................................................................................................................................................................................................................................................................................................................................................2502
5 Codes, Assembly Allocation, Capacities, Passat CC, CC from 2010.......................................................................................................................................................................................................................................................................................................................................................................................................................................................2503
6 Codes, Assembly Allocation, Capacities, Golf from MY 2009.............................................................................................................................................................................................................................................................................................................................................................................................................................................................2504
7 Codes, Assembly Allocation, Capacities, Sharan from MY 2011...........................................................................................................................................................................................................................................................................................................................................................................................................................................................2505
8 General Repair Information............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2506
8.1 General Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2506
8.2 Oil.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2506
8.3 Components......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2506
8.3.1 Rear Final Drive..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2506
8.3.3 O-Rings, Gaskets, Seals...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2507
8.3.4 Retainers.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2508
8.3.5 Nuts and Bolts............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2508
8.3.6 Bearings..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2509
8.3.7 Shims.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2509
9 Original Replacement Parts............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2510
39 – Final Drive, Differential..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2511
1 Vehicle Diagnostic Tester, Connecting and Selecting Functions.........................................................................................................................................................................................................................................................................................................................................................................................................................................................2511
2 Driveshaft, Golf from MY 2004 through 07/02/2007......................................................................................................................................................................................................................................................................................................................................................................................................................................................................2512
2.1 General Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2512
2.2 Overview - Driveshaft...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2512
2.3 Driveshaft, Removing and Installing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2514
2.4 Driveshaft, Servicing...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2519
2.5 Rear Flexible Disc, Removing and Installing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................2522
3 Driveshaft, Golf from MY 2004, from 07/02/2007........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2526
3.1 General Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2526
3.2 Overview - Driveshaft...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2526
3.3 Driveshaft, Removing and Installing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2527
4 Driveshaft, Passat from MY 2006 through 07/02/2007....................................................................................................................................................................................................................................................................................................................................................................................................................................................................2531
4.1 General Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2531
4.2 Driveshaft, Removing and Installing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2531
4.3 Front Driveshaft with Flexible Disc, Removing and Installing....................................................................................................................................................................................................................................................................................................................................................................................................................................................2535
4.4 Rear Flexible Disc, Removing and Installing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................2538
4.5 Driveshaft, Servicing...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2541
4.6 Tightening Specifications.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2544
5 Driveshaft, Passat from MY 2006, from 07/02/2007......................................................................................................................................................................................................................................................................................................................................................................................................................................................................2545
5.1 General Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2545
5.2 Overview - Driveshaft...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2545
5.3 Driveshaft, Removing and Installing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2546
6 Driveshaft, Tiguan from MY 2008.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2550
6.1 Overview - Driveshaft...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2550
6.2 Driveshaft, Removing and Installing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2551
6.3 Rear Flexible Disc, Removing and Installing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................2555
7 Driveshaft, Passat CC, CC from MY 2010 and Golf from MY 2009..........................................................................................................................................................................................................................................................................................................................................................................................................................................................2559
7.1 Overview - Driveshaft...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2559
7.2 Driveshaft, Removing and Installing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2560
7.3 Rear Flexible Disc, Removing and Installing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................2563
8 Driveshaft, Sharan from MY 2011.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2567
8.1 Overview - Driveshaft...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2567
8.2 Driveshaft, Removing and Installing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2568
8.3 Rear Flexible Disc, Removing and Installing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................2571
9 Rear Final Drive, Removing and Installing, Golf from MY 2004..........................................................................................................................................................................................................................................................................................................................................................................................................................................................2575
9.1 Rear Final Drive, Removing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2575
9.2 Rear Final Drive, Installing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2577
10 Rear Final Drive, Removing and Installing, Passat from MY 2006.......................................................................................................................................................................................................................................................................................................................................................................................................................................................2578
10.1 Rear Final Drive Identification................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2578
10.2 Rear Final Drive 02D/0AV, Removing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2578
10.3 Rear Final Drive 02D/0AV, Installing...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2581
10.4 Rear Final Drive 01Z, Removing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2584
10.5 Rear Final Drive 01Z, Installing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2586
11 Rear Final Drive, Removing and Installing, Tiguan from MY 2008.......................................................................................................................................................................................................................................................................................................................................................................................................................................................2589
11.1 Removing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2589
11.2 Installing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2594
12 Rear Final Drive, Removing and Installing, Passat CC, CC from MY 2010................................................................................................................................................................................................................................................................................................................................................................................................................................................2598
12.1 Removing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2598
12.2 Installing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2603
13 Rear Final Drive, Removing and Installing, Golf from MY 2009.........................................................................................................................................................................................................................................................................................................................................................................................................................................................2606
13.1 Removing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2606
13.2 Installing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2609
14 Rear Final Drive, Removing and Installing, Sharan from MY 2011.......................................................................................................................................................................................................................................................................................................................................................................................................................................................2612
15 Rear Final Drive Bonded Rubber Bushing, Replacing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................2615
15.1 Rear Final Drive Identification................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2615
15.2 Overview - Bonded Rubber Bushing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2615
15.3 Bonded Rubber Bushing, Removing................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2617
15.4 Bonded Rubber Bushing, Installing..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2618
15.5 Rear Final Drive Bonded Rubber Bushing, Replacing, Golf From MY 2004, Passat from MY 2006 with Final Drive 02D/0AV, Golf from MY 2009..........................................................................................................................................................................................................................................................................................................................................................................2619
15.6 Overview - Bonded Rubber Bushing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2619
15.7 Bonded Rubber Bushing, Removing and Installing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................2621
16 Flange Shaft Seals, Replacing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2624
16.1 Flange Shaft Seal, Removing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2624
16.2 Flange Shaft Seal, Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2625
17 Flange/Driveshaft Seal on Rear Final Drive, Replacing (Final Drive Installed)........................................................................................................................................................................................................................................................................................................................................................................................................................................2626
17.1 Removing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2626
17.2 Installing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2628
17.2.1 Tightening Specification.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2628
18 Haldex Clutch “Generation Haldex II”, Checking Function..............................................................................................................................................................................................................................................................................................................................................................................................................................................................2629
18.1 Haldex Clutch, Manual Transmission, Checking Function..........................................................................................................................................................................................................................................................................................................................................................................................................................................................2629
18.2 Haldex Clutch, Checking Function, Vehicles with DSG® Transmission..............................................................................................................................................................................................................................................................................................................................................................................................................................................2631
18.2.1 Closed Haldex Clutch, Function Test......................................................................................................................................................................................................................................................................................................................................................................................................................................................................2632
18.2.2 Open Haldex Clutch, Function Test........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2633
18.3 Haldex Clutch, Checking Function, Vehicles with Automatic Transmission.........................................................................................................................................................................................................................................................................................................................................................................................................................................2634
18.3.1 Function, Checking.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2634
19 “Haldex Generation IV” Haldex Clutch, Checking Function..............................................................................................................................................................................................................................................................................................................................................................................................................................................................2635
19.1 Function, Checking.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2635
20 Electrical/Electronic Components and Component Locations.............................................................................................................................................................................................................................................................................................................................................................................................................................................................2636
20.1 Electrical/Electronic Components and Component Locations, Golf from MY 2004....................................................................................................................................................................................................................................................................................................................................................................................................................................2636
20.2 Electrical/Electronic Components and Component Locations, Passat from MY 2006..................................................................................................................................................................................................................................................................................................................................................................................................................................2638
20.3 Electrical/Electronic Components and Component Locations, Tiguan, Passat CC, CC from MY 2010, Golf from MY 2009................................................................................................................................................................................................................................................................................................................................................................................................2639
21 All Wheel Drive Control Module -J492-, Golf from MY 2004 and Passat from MY 2006....................................................................................................................................................................................................................................................................................................................................................................................................................................2641
21.1 Overview - All Wheel Drive Control Module -J492-, Golf from MY 2004 and Passat from MY 2006....................................................................................................................................................................................................................................................................................................................................................................................................................2641
21.2 All Wheel Drive Control Module -J492-, Removing and Installing.................................................................................................................................................................................................................................................................................................................................................................................................................................................2642
21.2.1 All Wheel Drive Control Module -J492-, Removing..........................................................................................................................................................................................................................................................................................................................................................................................................................................................2642
21.2.2 All Wheel Drive Control Module -J492-, Installing........................................................................................................................................................................................................................................................................................................................................................................................................................................................2643
21.3 Haldex Clutch Pump -V181-, Removing and Installing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................2646
21.3.1 Removing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2646
21.3.2 Installing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2648
21.3.3 Tightening Specification.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2649
22 All Wheel Drive Control Module -J492-, Tiguan, Passat CC, CC from MY 2010, Golf from MY 2009........................................................................................................................................................................................................................................................................................................................................................................................................................2650
22.1 Overview - All Wheel Drive Control Module -J492-, Tiguan, Passat CC, CC from MY 2010, Golf from MY 2009........................................................................................................................................................................................................................................................................................................................................................................................................2650
22.2 All Wheel Drive Control Module -J492-, Removing and Installing.................................................................................................................................................................................................................................................................................................................................................................................................................................................2652
22.2.1 All Wheel Drive Control Module -J492-, Removing..........................................................................................................................................................................................................................................................................................................................................................................................................................................................2652
22.2.2 Installing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2653
22.3 Haldex Clutch Pump -V181-, Removing and Installing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................2655
22.3.1 Removing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2655
22.3.2 Installing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2656
22.3.3 Tightening Specification.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2657
23 Haldex Clutch........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2658
23.1 Overview - Haldex Clutch.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2658
24 Haldex Clutch, Removing and Installing, Golf from MY 2004 and Passat from MY 2006....................................................................................................................................................................................................................................................................................................................................................................................................................................2659
24.1 Haldex Clutch, Removing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2659
24.2 Haldex Clutch, Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2660
25 Haldex Clutch, Removing and Installing, Tiguan, Passat CC, CC from MY 2010, Golf from MY 2009........................................................................................................................................................................................................................................................................................................................................................................................................................2662
25.1 Haldex Clutch, Removing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2662
25.2 Haldex Clutch, Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2665
26 Haldex Clutch, Removing and Installing, Sharan from MY 2011..........................................................................................................................................................................................................................................................................................................................................................................................................................................................2667
26.1 Haldex Clutch, Removing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2667
26.2 Haldex Clutch, Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2669
27 Haldex Clutch (Generation II), Golf from MY 2004 and Passat from MY 2006.............................................................................................................................................................................................................................................................................................................................................................................................................................................2671
27.1 Overview - Haldex Clutch (Generation II), Disassembling and Assembling.........................................................................................................................................................................................................................................................................................................................................................................................................................................2671
27.2 Haldex Clutch Grooved Ball Bearing, Replacing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................2673
28 Haldex Clutch (Generation IV), Disassembling and Assembling, Tiguan, Passat CC, CC from MY 2010, and Golf from MY 2009...............................................................................................................................................................................................................................................................................................................................................................................................2678
28.1 Overview - Haldex Clutch (Generation IV), Disassembling and Assembling, Tiguan, Passat CC, CC from MY 2010, and Golf from MY 2009..............................................................................................................................................................................................................................................................................................................................................................................2678
29 Haldex Clutch Oil Filter, Removing and Installing, Golf from MY 2004 and Passat from MY 2006.........................................................................................................................................................................................................................................................................................................................................................................................................................2680
29.1 Removing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2680
29.2 Installing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2680
30 Oil Level in the Rear Final Drive, Checking or Adding Oil, Golf from MY 2004 and Passat from MY 2006.................................................................................................................................................................................................................................................................................................................................................................................................................2681
30.1 Oil Level in the Rear Final Drive, Checking or Adding Oil, Golf from MY 2004 and Passat from MY 2006...........................................................................................................................................................................................................................................................................................................................................................................................................2681
30.2 Tightening Specifications......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2682
31 Rear Final Drive Oil Level, Checking or Adding Oil, Tiguan, Passat CC, CC from MY 2010, and Golf from MY 2009........................................................................................................................................................................................................................................................................................................................................................................................................2683
32 Haldex Clutch Oil Level (Generation II), Checking or Adding Oil, Golf from MY 2004 and Passat from MY 2006...........................................................................................................................................................................................................................................................................................................................................................................................................2684
32.1 Haldex Clutch Oil Level, Checking..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2684
32.2 Haldex Clutch Oil, Filling.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2685
33 Oil Level in the Haldex Clutch (Generation IV), Checking or Adding Oil, Tiguan, Passat CC, CC from MY 2010, and Golf from MY 2009....................................................................................................................................................................................................................................................................................................................................................................................2688
33.1 Haldex Clutch Oil Level, Checking..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2688
33.2 Haldex Clutch Oil, Filling.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2688
34 Special Tools........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2691
35 Revision History.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2702
04-Automatic Transmission & DSG.pdf (p.2706-3013)...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2706
04-01 Direct Shift Gearbox (BPY,BUB,CCT,CBF,CBR,CJAA)...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2706
00 – General, Technical Data................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2710
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2710
1.1 Capacities......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2710
1.2 Transmission Allocation Codes...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2710
1.3 Transmission Allocation Codes...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2711
1.4 Transmission Allocation Codes...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2711
1.5 Transmission Allocation Codes...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2711
1.6 Transmission Allocation Codes...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2711
1.7 General Repair Information......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2711
1.8 Troubleshooting.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2714
1.9 Transmission Identification.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2716
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2719
2.1 Overview - Transmission Component...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2719
30 – Clutch.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2720
1 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2720
1.1 Overview - Direct Shift Gearbox.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2720
2 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2722
2.1 Clutch Cover, Removing..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2722
2.2 Clutch, Removing................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2724
2.3 Clutch, Installing and Adjusting................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2726
2.4 Clutch End Cover, Installing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2731
2.4.1 Covers that are Delivered without Bushings................................................................................................................................................................................................................................................................................................................................................................................................................................................................2732
2.4.2 Covers that are Delivered with Bushings...................................................................................................................................................................................................................................................................................................................................................................................................................................................................2734
3 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2736
34 – Controls, Housing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2737
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2737
1.1 Modifying the Adapter for Oil Filling -VAS6262A-................................................................................................................................................................................................................................................................................................................................................................................................................................................................2737
1.2 Transmission Oil Level, Checking and Filling....................................................................................................................................................................................................................................................................................................................................................................................................................................................................2737
1.3 DSG® Oil, Draining and Filling..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2739
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2743
2.1 DSG® Electric/Electronic Components and Locations...............................................................................................................................................................................................................................................................................................................................................................................................................................................................2743
2.2 Selector Lever, Manual Release..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2744
2.3 Selector Lever Cable, Adjusting.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2744
2.4 Overview - Selector Mechanism, through 02/2009..................................................................................................................................................................................................................................................................................................................................................................................................................................................................2745
2.5 Overview - Selector Mechanism, from 03/2009.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................2747
3 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2749
3.1 Fastener Tightening Specifications..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2749
3.2 Transmission to Engine Tightening Specifications................................................................................................................................................................................................................................................................................................................................................................................................................................................................2750
3.3 Transmission to Engine Tightening Specifications................................................................................................................................................................................................................................................................................................................................................................................................................................................................2751
3.4 Transmission to Engine Tightening Specifications................................................................................................................................................................................................................................................................................................................................................................................................................................................................2752
3.5 Transmission to Engine Tightening Specifications................................................................................................................................................................................................................................................................................................................................................................................................................................................................2753
3.6 Transmission to Engine Tightening Specifications................................................................................................................................................................................................................................................................................................................................................................................................................................................................2754
4 Diagnosis and Testing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2756
4.1 Selector Lever Cable, Checking..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2756
4.2 Selector Mechanism, Checking....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2756
5 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2758
5.1 Selector Lever Handle...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2758
5.2 Handle Button, Moving Into the Installed Position...............................................................................................................................................................................................................................................................................................................................................................................................................................................................2760
5.3 Selector Lever Cable, through 02/2009...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2762
5.4 Selector Mechanism with Housing, from 03/2009...................................................................................................................................................................................................................................................................................................................................................................................................................................................................2769
5.5 Selector Mechanism without Housing, from 03/2009................................................................................................................................................................................................................................................................................................................................................................................................................................................................2771
5.6 Transmission Oil Cooler.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2773
5.7 Oil Pump........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2775
5.8 Selector Shaft Lever Seal, Transmission Removed.................................................................................................................................................................................................................................................................................................................................................................................................................................................................2777
5.9 DSG Transmission Mechatronic -J743-, Transmission Installed.....................................................................................................................................................................................................................................................................................................................................................................................................................................................2778
5.10 DSG Transmission Mechatronic -J743-, Transmission Removed......................................................................................................................................................................................................................................................................................................................................................................................................................................................2785
5.11 Transmission Input Speed Sensor -G182- and Clutch Oil Temperature Sensor -G509-................................................................................................................................................................................................................................................................................................................................................................................................................................2790
5.12 Oil Filter.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2791
5.13 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2792
5.14 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2797
5.15 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2801
5.16 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2805
5.17 Bevel Box......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2812
5.18 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2816
5.19 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2821
5.20 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2827
5.21 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2831
5.22 Transmission, Transporting and Securing to the Assembly Stand..................................................................................................................................................................................................................................................................................................................................................................................................................................................2839
5.23 Transmission, Installing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2840
6 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2842
7 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2845
8 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2848
9 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2851
10 Special Tools........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2855
11 Special Tools........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2859
12 Special Tools........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2862
13 Special Tools........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2864
39 – Final Drive, Differential..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2867
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2867
1.1 Bevel Box Gear Oil Level, Checking and Filling..................................................................................................................................................................................................................................................................................................................................................................................................................................................................2867
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2870
2.1 Overview - Transmission and Bevel Box Seals.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................2870
2.2 Overview - Flange Shaft.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2871
2.3 Overview - Flange Shaft and Bevel Box Seals.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................2872
3 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2874
3.1 Left Flange Shaft and Seal......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2874
3.2 Right Stub/Flange Shaft and Seal, FWD...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2875
3.3 Right Flange Shaft, AWD.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2876
3.4 Right Flange Shaft Seal.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2878
3.5 Right Flange Shaft Seal, Outside of Bevel Box...................................................................................................................................................................................................................................................................................................................................................................................................................................................................2879
3.6 Right Flange Shaft Needle Bearing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2880
3.7 Bevel Box Output Flange and Seal................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2881
3.8 Seal, Between the Transmission and Bevel Box, Transmission Side.................................................................................................................................................................................................................................................................................................................................................................................................................................................2884
3.9 Seal, Between the Transmission and Bevel Box, Bevel Box Side....................................................................................................................................................................................................................................................................................................................................................................................................................................................2885
4 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2886
5 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2887
6 Revision History......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2892
04-02 Direct Shift Gearbox (BUB,CBE)............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2896
00 – General, Technical Data................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2900
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2900
1.1 General Repair Information......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2900
1.2 Troubleshooting.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2903
1.2.1 Control Module Malfunction Behavior.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................2903
1.2.2 Special Troubleshooting Information.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................2904
1.3 Transmission Identification.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2905
1.3.1 Reading Transmission Code Letters.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2906
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2908
2.1 Transmission Component Overview.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2908
3 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2909
3.1 Transmission Allocation Codes...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2909
3.1.1 GTI, MY 2006 through 2009.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2909
3.1.2 Golf/GTI, from MY 2010....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2909
3.1.3 Passat....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2909
3.1.4 Passat CC.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2909
3.2 Capacities......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2909
4 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2911
30 – Clutch.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2912
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2912
1.1 Clutch..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2912
2 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2913
2.1 Fastener Tightening Specifications..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2913
3 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2914
3.1 Clutch Cover, Removing..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2914
3.2 Clutch Cover, Installing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2916
3.2.1 Covers Delivered without Bushings.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2916
3.2.2 Covers Delivered with Bushings............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2918
3.3 Clutch, Removing................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2919
3.4 Multi-Plate Clutch, Preparing for Installation..................................................................................................................................................................................................................................................................................................................................................................................................................................................................2920
3.5 Clutch, Installing and Adjusting................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2921
4 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2926
34 – Controls, Housing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2927
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2927
1.1 Selector Lever Cable, Adjusting.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2927
1.2 Transmission, Transporting and Securing to Assembly Stand.......................................................................................................................................................................................................................................................................................................................................................................................................................................................2928
1.3 Fluid Filter Changing and Fluid Level, Adjusting................................................................................................................................................................................................................................................................................................................................................................................................................................................................2929
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2933
2.1 Electric and Electronic Component Locations.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................2933
2.2 Selector Lever Manual Release...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2933
2.3 Selector Mechanism Overview, through 02.2009....................................................................................................................................................................................................................................................................................................................................................................................................................................................................2934
2.4 Selector Mechanism Overview, from 03.2009.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................2936
3 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2938
3.1 Fastener Tightening Specifications..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2938
3.2 Transmission to Engine Tightening Specifications................................................................................................................................................................................................................................................................................................................................................................................................................................................................2939
3.2.1 GTI through 2009, Golf with 2.0L TDI......................................................................................................................................................................................................................................................................................................................................................................................................................................................................2940
3.2.2 GTI from 2010, Passat and Passat CC.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................2941
4 Diagnosis and Testing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2942
4.1 Selector Mechanism, Checking....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2942
4.2 Selector Lever Cable, Checking..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2943
5 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2944
5.1 Shift Handle with Cover.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2944
5.2 Mechatronic, Transmission Installed.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2945
5.3 Mechatronic, Transmission Removed...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................2951
5.4 Transmission Input Speed and Clutch Oil Temperature Sensor......................................................................................................................................................................................................................................................................................................................................................................................................................................................2956
5.5 Transmission Oil Cooler.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2956
5.6 Oil Pump........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2959
5.7 Selector Shaft Lever Seal.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2961
5.8 Selector Lever Cable, through 02.2009...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................2962
5.9 Selector Lever and Mechanism with Cable, from 03.2009...........................................................................................................................................................................................................................................................................................................................................................................................................................................................2969
5.10 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2970
5.11 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2973
5.12 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2979
5.13 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2985
5.14 Transmission, Removing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2990
5.15 Transmission, Installing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2996
6 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2998
39 – Final Drive, Differential..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3002
1 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3002
1.1 Flange Shaft Assembly Overview..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3002
2 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3004
2.1 Fastener Tightening Specifications..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3004
3 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3005
3.1 Left Flange Shaft and Seal......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3005
3.2 Right Stub/Flange Shaft and Seal................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3006
3.3 Right Flange Shaft Needle Bearing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3008
4 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3009
05-Steering & Suspension.pdf (p.3014-3857)..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3014
05-01 Suspension,Wheels & Steering..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3014
00 – General, Technical Data................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3020
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3020
1.1 Evaluating Suspension of Vehicles Involved in Accidents.........................................................................................................................................................................................................................................................................................................................................................................................................................................................3020
1.2 Wheels, Tires and Snow Chains...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3021
40 – Front Suspension.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3022
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3022
1.1 Longitudinal Member Threads, Servicing..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3022
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3023
2.1 Front Suspension Overview.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3023
2.2 Wheel Bearing, Lifting to Curb Weight Position..................................................................................................................................................................................................................................................................................................................................................................................................................................................................3024
2.3 Subframe, Stabilizer Bar and Control Arms Overview..............................................................................................................................................................................................................................................................................................................................................................................................................................................................3026
2.4 Overview - Left Front Level Control System Sensor -G78-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................3031
2.5 Subframe and Consoles, Securing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3031
2.6 Subframe, Lowering..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3033
2.7 Wheel Bearing Overview..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3036
2.8 Suspension Strut Overview.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3039
2.9 Drive Axle Twelve-Point Bolt with Ribs, Loosening and Tightening................................................................................................................................................................................................................................................................................................................................................................................................................................................3039
2.10 Drive Axle Twelve-Point Bolt without Ribs, Loosening and Tightening............................................................................................................................................................................................................................................................................................................................................................................................................................................3040
2.11 Drive Axle Overview............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3041
2.12 Drive Axle Heat Shields........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3043
2.13 Drive Axle Overview, with CV Joint VL90 and VL100..............................................................................................................................................................................................................................................................................................................................................................................................................................................................3043
2.14 Drive Axle Overview, with Bolted CV Joint VL107................................................................................................................................................................................................................................................................................................................................................................................................................................................................3046
2.15 Drive Axle Overview, with Mounted CV Joint VL107...............................................................................................................................................................................................................................................................................................................................................................................................................................................................3049
2.16 Drive Axle Overview with Triple Roller Joint AAR3300i..........................................................................................................................................................................................................................................................................................................................................................................................................................................................3051
3 Diagnosis and Testing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3053
3.1 Ball Joint, Checking............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3053
3.2 Outer CV Joint, Checking........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3053
3.3 Inner CV Joint, Checking........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3054
4 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3057
4.1 Left Front Level Control System Sensor -G78-....................................................................................................................................................................................................................................................................................................................................................................................................................................................................3057
4.2 Subframe without Steering Gear..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3058
4.3 Subframe with Steering Gear.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3062
4.4 Subframe, Servicing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3066
4.5 Ball Joint......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3073
4.6 Control Arm with Mounting Bracket...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3076
4.7 Left Control Arm with Mounting Bracket, DSG and Automatic Transmission..........................................................................................................................................................................................................................................................................................................................................................................................................................................3079
4.8 Control Arm Bonded Rubber Bushing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3084
4.9 Mounting Bracket with Control Arm Bearing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3086
4.10 Stabilizer Bar.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3086
4.11 Wheel Bearing Unit, 3-Point Mount..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3091
4.12 Wheel Bearing Unit, 4-Point Mount..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3092
4.13 Wheel Bearing Housing..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3095
4.14 Suspension Strut...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3099
4.15 Drive Axle with CV Joint.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3105
4.16 Left Drive Axle with Mounted CV Joint..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3109
4.17 Right Drive Axle with Mounted CV Joint.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3114
4.18 Drive Axle with Tripod Joint AAR3300i..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3119
5 Disassembly and Assembly..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3123
5.1 Suspension Strut................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3123
5.2 Drive Axle with CV Joint VL90 and VL100.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3124
5.3 Drive Axle with Bolted CV Joint VL107...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3127
5.4 Drive Axle with Mounted CV Joint VL107..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3130
5.5 Drive Axle with Triple Roller Joint AAR3300i....................................................................................................................................................................................................................................................................................................................................................................................................................................................................3132
6 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3137
42 – Rear Suspension........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3145
1 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3145
1.1 Front Wheel Drive (FWD).........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3145
1.1.1 Rear Suspension Overview..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3145
1.1.2 Rear Axle, Lifting to Curb Weight Position................................................................................................................................................................................................................................................................................................................................................................................................................................................................3146
1.1.3 Subframe, Transverse Link and Tie Rod Overview............................................................................................................................................................................................................................................................................................................................................................................................................................................................3148
1.1.4 Overview - Left Rear Level Control System Sensor -G76-, FWD...............................................................................................................................................................................................................................................................................................................................................................................................................................................3151
1.1.5 Wheel Bearing Housing and Trailing Arm Overview...........................................................................................................................................................................................................................................................................................................................................................................................................................................................3152
1.1.6 Shock Absorber and Coil Spring Overview...................................................................................................................................................................................................................................................................................................................................................................................................................................................................3154
1.1.7 Stabilizer Bar Overview...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3155
1.2 All Wheel Drive (AWD)...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3156
1.2.1 Rear Suspension Overview..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3156
1.2.2 Rear Axle, Lifting to Curb Weight Position................................................................................................................................................................................................................................................................................................................................................................................................................................................................3158
1.2.3 Subframe and Final Drive Overview.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3160
1.2.4 Transverse Link and Tie Rod Overview......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3162
1.2.5 Left Rear Level Control System Sensor Overview............................................................................................................................................................................................................................................................................................................................................................................................................................................................3165
1.2.6 Wheel Bearing Housing and Trailing Arm Overview...........................................................................................................................................................................................................................................................................................................................................................................................................................................................3166
1.2.7 Shock Absorber and Coil Spring Overview...................................................................................................................................................................................................................................................................................................................................................................................................................................................................3169
1.2.8 Stabilizer Bar Overview...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3170
1.2.9 Drive Axle Overview.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3171
1.2.10 Drive Axle Twelve-Point Bolt with Ribs, Loosening and Tightening.........................................................................................................................................................................................................................................................................................................................................................................................................................................3173
1.2.11 Drive Axle Twelve-Point Bolt without Ribs, Loosening and Tightening......................................................................................................................................................................................................................................................................................................................................................................................................................................3174
2 Diagnosis and Testing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3176
2.1 Outer CV Joint, Checking........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3176
2.2 Inner CV Joint, Checking........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3177
3 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3179
3.1 Front Wheel Drive (FWD).........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3179
3.1.1 Subframe..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3179
3.1.2 Left Rear Level Control System Sensors -G76-, FWD.........................................................................................................................................................................................................................................................................................................................................................................................................................................................3183
3.1.3 Upper Transverse Link.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3183
3.1.4 Lower Transverse Link.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3185
3.1.5 Tie Rod...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3186
3.1.6 Wheel Bearing Housing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3188
3.1.7 Wheel Bearing Housing Bonded Rubber Bushing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................3191
3.1.8 Wheel Bearing and Wheel Hub...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3193
3.1.9 Trailing Arm with Mounting Bracket........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3195
3.1.10 Trailing Arm Bonded Rubber Bushing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3198
3.1.11 Coil Spring..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3200
3.1.12 Shock Absorber...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3201
3.1.13 Stabilizer Bar...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3202
3.2 All Wheel Drive (AWD)...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3204
3.2.1 Subframe..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3204
3.2.2 Subframe Bonded Rubber Bushings...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3208
3.2.3 Left Rear Level Control System Sensors....................................................................................................................................................................................................................................................................................................................................................................................................................................................................3216
3.2.4 Upper Transverse Link.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3216
3.2.5 Lower Transverse Link, Removing and Installing............................................................................................................................................................................................................................................................................................................................................................................................................................................................3218
3.2.6 Tie Rod...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3219
3.2.7 Wheel Bearing Housing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3222
3.2.8 Wheel Bearing Housing Bonded Rubber Bushing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................3225
3.2.9 Wheel Bearing and Wheel Hub...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3227
3.2.10 Trailing Arm with Mounting Bracket.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3227
3.2.11 Trailing Arm Bonded Rubber Bushing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3230
3.2.12 Coil Spring..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3232
3.2.13 Shock Absorber...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3233
3.2.14 Stabilizer Bar...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3234
3.2.15 Drive Axle...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3236
4 Disassembly and Assembly..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3241
4.1 Shock Absorber, FWD.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3241
4.2 Shock Absorber, AWD.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3242
4.3 Drive Axle......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3244
5 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3248
43 – Self-Leveling Suspension...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3256
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3256
1.1 Dampening Adjustment Button.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3256
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3257
2.1 Adaptive Chassis DCC Components and Installation Locations......................................................................................................................................................................................................................................................................................................................................................................................................................................................3257
2.2 Overview - Front Left/Right Level Control System Sensor -G78/G289- for the Adaptive Chassis DDC.................................................................................................................................................................................................................................................................................................................................................................................................................3260
2.3 Overview - Left Rear Level Control System Sensor -G76- Adaptive Chassis DCC, FWD................................................................................................................................................................................................................................................................................................................................................................................................................................3261
2.4 Overview - Left Rear Level Control System Sensor -G76-, Adaptive Chassis DCC, AWD...............................................................................................................................................................................................................................................................................................................................................................................................................................3262
2.5 Left Front Axle Wire Routing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3263
2.6 Right Front Axle Wire Routing...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3264
2.7 Rear Axle Wire Routing..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3265
2.8 Suspension Strut Overview.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3266
2.9 Shock Absorber Overview, FWD....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3268
2.10 Shock Absorber Overview, AWD...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3269
3 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3271
3.1 Left and Right Front Body Acceleration Sensor...................................................................................................................................................................................................................................................................................................................................................................................................................................................................3271
3.2 Left and Right Front Body Acceleration Sensor Retainer..........................................................................................................................................................................................................................................................................................................................................................................................................................................................3272
3.3 Left and Right Front Level Control System Sensors -G78/G289-....................................................................................................................................................................................................................................................................................................................................................................................................................................................3273
3.4 Left Rear Level Control System Sensor -G76- for Adaptive Chassis DCC, FWD.......................................................................................................................................................................................................................................................................................................................................................................................................................................3274
3.5 Left Rear Level Control System Sensor -G76-, Adaptive Chassis DCC, AWD..........................................................................................................................................................................................................................................................................................................................................................................................................................................3275
3.6 Electronic Damping Control Module -J250-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3276
3.7 Electronic Damping Control Module Bracket.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3276
3.8 Suspension Strut................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3277
3.9 Rear Body Acceleration Sensor, FWD..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3284
3.10 Rear Body Acceleration Sensor, AWD.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3285
3.11 Shock Absorber, FWD............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3285
3.12 Shock Absorber, AWD............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3287
4 Disassembly and Assembly..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3290
4.1 Shock Absorber, FWD.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3290
4.2 Shock Absorber, AWD.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3291
5 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3294
44 – Wheels, Tires, Wheel Alignment.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3297
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3297
1.1 General Repair Information......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3297
1.2 Wheel and Tire Assembly Requirements............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3298
1.3 Tire Pressure Monitoring System Safety Precautions..............................................................................................................................................................................................................................................................................................................................................................................................................................................................3299
1.4 Tire and Wheel Changing, with Tire Pressure Monitoring System...................................................................................................................................................................................................................................................................................................................................................................................................................................................3299
1.5 Run-Flat Tires Safety Precautions...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3300
1.6 Tire Pressure Monitoring System, Indirect System................................................................................................................................................................................................................................................................................................................................................................................................................................................................3300
1.7 Tire Pressure Monitoring System, Direct System..................................................................................................................................................................................................................................................................................................................................................................................................................................................................3302
1.8 Wheel Alignment.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3303
1.9 Wheel Alignment Prerequisites...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3304
1.10 Vehicle Data Label.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3304
1.11 Wheel Repair Kit...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3305
1.12 Tire Sealant...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3305
1.13 Tire Sealant Disposal..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3306
1.14 Wheel Centering Seat, Protecting against Corrosion.............................................................................................................................................................................................................................................................................................................................................................................................................................................................3306
1.15 Wheels and Tires, Causes for Vibration.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3306
1.16 Balancing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3307
1.17 Road Test, Performing before Balancing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3307
1.18 Stationary Balancing Machine...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3307
1.19 Vibration Control Tire Balancer................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3309
1.20 Finish Balancer................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3309
1.21 Wheels and Tires, Radial Lateral Run Out.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3310
1.22 Matched Mounting...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3311
1.23 Flat Spots in Tires from Standing..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3312
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3314
2.1 Tire Pressure Sensor Overview...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3314
2.2 Wheel Alignment Measurement Preparations........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3315
2.3 Vehicle Alignment Procedure Overview............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3315
2.4 Wheel, Changing and Mounting....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3316
2.5 Wheel Mounting..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3318
3 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3319
3.1 Wheel Bolt Tightening Specification.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3319
3.2 Wheel Alignment Specified Values................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3319
4 Diagnosis and Testing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3322
4.1 Front Axle Camber, Correcting...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3322
4.2 Rear Axle Camber, Adjusting.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3323
4.3 Rear Axle Toe, Adjusting........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3324
4.4 Front Axle Toe, Adjusting.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3325
4.5 Steering Angle Sensor, Basic Setting............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3326
4.6 Wheel and Tire Radial and Lateral Run Out, Checking with Tire Dial Gauge........................................................................................................................................................................................................................................................................................................................................................................................................................................3326
4.7 Disc Wheel, Checking Radial and Lateral Run Out.................................................................................................................................................................................................................................................................................................................................................................................................................................................................3327
5 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3328
5.1 Tire Pressure Sensor............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3328
5.2 Tires, Wheels with Tire Pressure Monitoring System..............................................................................................................................................................................................................................................................................................................................................................................................................................................................3329
5.2.1 Tire, Pressing Off........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3329
5.2.2 Tires, Dismounting........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3330
5.2.3 Tires, Mounting...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3330
5.3 Tires, with Run-Flat Tires......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3332
5.3.1 Tire, Pressing Off........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3332
5.3.2 Tires, Dismounting........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3332
5.3.3 Tires, Mounting...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3334
5.4 Tire, Sealed with Sealant.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3336
5.4.1 Tires, Removing...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3336
5.4.2 Tires, Mounting...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3336
6 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3337
48 – Steering...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3339
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3339
1.1 General Repair Information......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3339
1.2 Electromechanical Steering Gear, Servicing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3340
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3341
2.1 Steering Column Overview, Vehicles without Knee Airbags.........................................................................................................................................................................................................................................................................................................................................................................................................................................................3341
2.2 Steering Column Overview, Vehicles with Knee Airbags............................................................................................................................................................................................................................................................................................................................................................................................................................................................3342
2.3 Steering Column, Handling and Transporting......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3342
2.4 Electromechanical Steering Gear Overview........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3344
3 Diagnosis and Testing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3346
3.1 Steering Column, Checking for Damage............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3346
4 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3347
4.1 Steering Wheel..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3347
4.2 Steering Column, Vehicles without Knee Airbags..................................................................................................................................................................................................................................................................................................................................................................................................................................................................3349
4.3 Steering Column, Vehicles with Knee Airbags.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................3356
4.4 Steering Gear...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3363
4.5 Boot............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3371
4.6 Tie Rod, Removing and Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3373
5 Disassembly and Assembly..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3376
5.1 Electromechanical Steering Gear.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3376
6 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3377
7 Revision History......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3379
05-02 Wheel and Tire Guide General Information..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3383
44 – Wheels, Tires, Wheel Alignment.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3387
1 Specifications for Retrofitting Wheel and Tire Combinations...........................................................................................................................................................................................................................................................................................................................................................................................................................................................3387
1.1 Legal Requirements..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3387
1.1.1 Permitted Wheel and Tire Combinations in Germany..........................................................................................................................................................................................................................................................................................................................................................................................................................................................3387
1.1.2 Vehicles with Tire Pressure Monitoring System.............................................................................................................................................................................................................................................................................................................................................................................................................................................................3387
1.2 Technical Requirements..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3388
1.3 Load Rating Depending on Speed and Winter Tires.................................................................................................................................................................................................................................................................................................................................................................................................................................................................3388
1.4 Vehicle Registration Documents Since 01/10/2005.................................................................................................................................................................................................................................................................................................................................................................................................................................................................3390
1.5 Certificate of Conformity.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3391
1.6 EU Type Approval Number, Sales Code and Sales or Trade Name.....................................................................................................................................................................................................................................................................................................................................................................................................................................................3391
2 Handling Problems.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3393
2.1 Driving Noise...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3393
2.1.1 Tires, Rolling Noises, General Information................................................................................................................................................................................................................................................................................................................................................................................................................................................................3393
2.1.2 Wear Spots................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3394
2.2 Vehicle Pulls to One Side.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3394
2.2.1 General Information.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3394
2.2.2 Taper.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3395
2.2.3 Corrective Action When Vehicle Pulls to One Side..........................................................................................................................................................................................................................................................................................................................................................................................................................................................3396
2.2.4 Targeted Rotating of Wheels for Non-Directional Tires.....................................................................................................................................................................................................................................................................................................................................................................................................................................................3397
2.2.5 Wheels, Targeted Rotating for Directional Tires...........................................................................................................................................................................................................................................................................................................................................................................................................................................................3398
2.3 Vibration.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3399
2.3.1 Vibration, Causes for Vibration...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3399
2.3.2 Vibration, Road Test, Performing Before Balancing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................3399
2.3.3 Vibration, Vibration Control System.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3400
2.4 Flat Spots, Correcting..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3400
3 Tires, Evaluating.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3401
3.1 Flat Spots......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3401
3.2 Cracking........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3401
3.3 Heel and Toe Wear...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3402
3.4 Wear Spots......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3402
3.5 Tire Sidewall Swelling..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3402
3.6 Cuts............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3404
3.7 Foreign Object Damage...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3404
3.8 Disintegrated Tread.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3404
3.9 Tires, Damage from Low Tire Pressure............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3405
3.10 Inspecting Tires...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3405
3.11 Mounting Damage................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3406
4 Tire Wear.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3408
4.1 Tire Service Life, Influences...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3408
4.2 Heel and Toe Wear...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3409
4.3 High Speed Tires, Wear Characteristics..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3409
4.4 Tread Depth, Measuring..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3410
4.5 Tire Wear, One Sided............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3410
4.6 Tire Wear, Outer Shoulder.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3413
4.7 Diagonal Washouts...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3414
4.8 Tire Wear, Center...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3414
4.9 Permitted Tread Depth - Variance................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3415
5 Component Overview....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3416
5.1 Overview - Wheel................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3416
5.1.1 Overview - Wheel, Standard................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3416
5.1.2 Overview - Wheel, RAX.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3417
6 Tires, Mounting.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3419
6.1 Tires, Dismounting..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3419
6.2 Tire Sealant, Removing..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3419
6.3 Tires, Dismounting..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3420
6.3.1 Tires, Dismounting, Wheels without and with Tire Pressure Monitoring System...............................................................................................................................................................................................................................................................................................................................................................................................................................3420
6.3.2 Tires, Dismounting, Run-Flat Tires and Ultra High Performance Tires.......................................................................................................................................................................................................................................................................................................................................................................................................................................3421
6.4 Tires, Bringing to Mounting Temperature.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3423
6.5 Tires, Mounting.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3423
6.5.1 Tires, Mounting, Wheels without and with Tire Pressure Monitoring System..................................................................................................................................................................................................................................................................................................................................................................................................................................3423
6.5.2 Tires, Mounting, Run-Flat Tires and Ultra High Performance Tires..........................................................................................................................................................................................................................................................................................................................................................................................................................................3425
6.6 Tires and Rims, Matching........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3427
6.7 Wheel, Balancing................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3428
6.7.1 Wheel, Balancing on Stationary Balancing Machine..........................................................................................................................................................................................................................................................................................................................................................................................................................................................3428
6.7.2 Wheel, Balancing with Fine Balancing Machine (Finish Balancer)............................................................................................................................................................................................................................................................................................................................................................................................................................................3431
6.7.3 Wheel, Balancing, Tire and Wheel Radial and Lateral Run-Out, Checking.....................................................................................................................................................................................................................................................................................................................................................................................................................................3432
6.7.4 Wheel Balancing, Rim Radial and Lateral Run-Out, Checking.................................................................................................................................................................................................................................................................................................................................................................................................................................................3434
7 Wheel, Mounting.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3435
7.1 Wheel, Mounting.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3435
7.1.1 Wheel, Mounting, Volkswagen Assembly Instructions.........................................................................................................................................................................................................................................................................................................................................................................................................................................................3435
7.1.2 Wheel, Mounting, Audi Assembly Instructions...............................................................................................................................................................................................................................................................................................................................................................................................................................................................3438
7.1.3 Wheel Mounting, Position of Anti-Theft Wheel Bolts on Steel Wheels........................................................................................................................................................................................................................................................................................................................................................................................................................................3444
8 Tire Information......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3445
8.1 Side Wall Lettering.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3445
8.1.1 Side Wall Lettering, Standard Tire........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3445
8.1.2 Run-Flat Tire (PAX), Lettering On Side Wall...............................................................................................................................................................................................................................................................................................................................................................................................................................................................3447
8.2 Tire Dimension..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3447
8.3 Load index (LI).................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3448
8.4 Speed Rating....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3448
8.5 EU Tire Label...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3449
8.5.1 EU Tire Label, Short Overview.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3449
8.5.2 EU Tire Label, Goals......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3450
8.5.3 EU Tire Label, Categories.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3451
8.6 Overview - Radial Ply Tire......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3454
8.6.1 Cross-Section of a Radial Ply Tire........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3454
8.6.2 Run-Flat Tire, Structure and Identification, SST Tire.....................................................................................................................................................................................................................................................................................................................................................................................................................................................3455
8.6.3 Run-Flat Tire, Seal Inside-Technology.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................3456
8.6.4 Run-Flat Tire, Overview of a PAX Tire.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................3458
8.7 Tires with Emergency Running Characteristics, SST (Self-Supporting Tire)........................................................................................................................................................................................................................................................................................................................................................................................................................................3460
8.7.1 Run-Flat Tire, General Information........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3460
8.7.2 Run-Flat Tire, Retrofitting/Conditions for use of Run-Flat Tires..........................................................................................................................................................................................................................................................................................................................................................................................................................................3461
8.7.3 Run-Flat Tire, Repair.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3462
8.8 Run-Flat Tire PAX...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3462
8.8.1 Run-Flat Tire PAX, Tire Inflation.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3462
8.8.2 Run-Flat Tire PAX, Wheel Alignment and Adjustment.........................................................................................................................................................................................................................................................................................................................................................................................................................................................3463
8.8.3 Run-Flat Tire PAX, Repairing..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3463
8.8.4 Run-Flat Tire PAX, Examining..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3463
8.9 Tires, Storing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3464
8.10 Tires, Reinforced, Extra Load..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3465
8.11 Winter tires...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3465
8.12 Winter Tires with Speed Symbol V...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3467
8.13 Rolling Resistance Tires.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3468
8.14 Tires, Aging...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3468
8.15 Tires with Rim Protector.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3469
8.16 Tire Sizes, AWD Vehicles.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3470
8.17 Increasing Temperature Due To Low Tire Pressure................................................................................................................................................................................................................................................................................................................................................................................................................................................................3470
9 Rim Information.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3471
9.1 Overview - Rim..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3471
9.2 Identification..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3472
9.3 Composite Wheels................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3472
9.4 Light Alloy Wheels, Care and Maintenance........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3472
9.5 Light Alloy Wheels, Preparing...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3473
9.6 Hub Cap for Alloy Wheels with Open Threaded Connection, Removing and Installing.................................................................................................................................................................................................................................................................................................................................................................................................................................3474
9.7 Decorative Trims, Replacing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3474
9.7.1 Decorative Trims, Replacing, Bonded Decorative Trims......................................................................................................................................................................................................................................................................................................................................................................................................................................................3474
9.7.2 Decorative Trims, Replacing, Bolted Decorative Trims......................................................................................................................................................................................................................................................................................................................................................................................................................................................3477
9.8 Valve, Removing and Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3479
9.8.1 Valve, Removing and Installing, Valve Explanations........................................................................................................................................................................................................................................................................................................................................................................................................................................................3479
9.8.2 Valve, Removing and Installing, Rubber Valve..............................................................................................................................................................................................................................................................................................................................................................................................................................................................3480
9.8.3 Valve, Removing and Installing, Metal Valve...............................................................................................................................................................................................................................................................................................................................................................................................................................................................3480
9.9 Run-Flat System PAX.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3481
9.9.1 Run-Flat System PAX, Support Ring.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3481
9.9.3 Run-Flat System PAX, Examining Support Ring...............................................................................................................................................................................................................................................................................................................................................................................................................................................................3481
10 Tire Pressure Monitoring System......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3483
10.1 Tire Pressure Monitoring System................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3483
10.2 Tire Pressure Monitoring System................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3483
11 Tire Pressure Sensor.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3484
11.1 Overview - Tire Pressure Monitoring Sensor.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................3484
11.1.1 Overview - Tire Pressure Monitoring Sensor with Valve....................................................................................................................................................................................................................................................................................................................................................................................................................................................3484
11.1.2 Overview - Tire Pressure Monitoring Sensor without Valve.................................................................................................................................................................................................................................................................................................................................................................................................................................................3485
11.2 Tire Pressure Monitoring Sensor, Removing and Installing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................3487
11.2.1 Tire Pressure Monitoring Sensor with Valve, Removing and Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................3487
11.2.2 Tire Pressure Monitoring Sensor without Metal Valve, Removing and Installing, Service Version............................................................................................................................................................................................................................................................................................................................................................................................................3488
11.2.3 Tire Pressure Monitoring Sensor without Valve, Removing and Installing, Vehicle Before Customer Delivery.................................................................................................................................................................................................................................................................................................................................................................................................3489
11.2.4 Tire Pressure Sensor and Metal Valve, Removing and Installing............................................................................................................................................................................................................................................................................................................................................................................................................................................3491
11.2.6 Siemens Wheel Electronics Tire Pressure Monitoring Sensor, Removing and Installing.......................................................................................................................................................................................................................................................................................................................................................................................................................3493
12 Tire Sealant.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3494
12.1 Tire Sealant, Expiration Date..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3494
12.2 Tire Sealant, Disposal.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3494
13 Wheel Bolts..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3495
13.1 Wheel Bolt Versions............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3495
13.2 Wheel Bolts, Anti-Theft Wheel Bolt.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3496
13.3 Wheel Bolts, Master Sets for Anti-Theft Wheel Bolts............................................................................................................................................................................................................................................................................................................................................................................................................................................................3496
14 Snow Chains..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3498
14.1 Snow Chains, Assembly and Replacing............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3498
15 Emergency Wheels.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3499
15.1 Spare Wheel Notes..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3499
16 Special Tools........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3500
17 Revision History.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3502
05-03 Wheel and Tire Guide 2009.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3506
44 – Wheels, Tires, Wheel Alignment.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3510
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3510
1.1 Wheels and Tires................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3510
1.2 Legal and Technical Requirements for Retrofitting Wheel and Tire Combinations...................................................................................................................................................................................................................................................................................................................................................................................................................................3511
1.2.1 Legal Requirements, Retrofitting Wheel and Tire Combinations..............................................................................................................................................................................................................................................................................................................................................................................................................................................3511
1.2.2 Technical Requirements, Retrofitting Wheel and Tire Combinations..........................................................................................................................................................................................................................................................................................................................................................................................................................................3512
1.2.3 Additional Wheel Housing Enlargement, FLAPS...............................................................................................................................................................................................................................................................................................................................................................................................................................................................3513
1.2.4 80 Series Tires...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3513
1.3 Documents and Designations......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3513
1.3.1 New Vehicle Registration Documents Since October 1, 2005..................................................................................................................................................................................................................................................................................................................................................................................................................................................3513
1.3.2 Certificate of Conformity.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3514
1.3.3 EU Type Approval Number, Sales Type and Sales or Trade Name...............................................................................................................................................................................................................................................................................................................................................................................................................................................3515
1.4 Tire Wear and Performance.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3516
1.4.1 Wear and Performance......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3516
1.4.3 High Speed Tires, Wear Characteristics....................................................................................................................................................................................................................................................................................................................................................................................................................................................................3517
1.4.4 Tire Service Life, Influences.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3517
1.4.5 Driving Style.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3518
1.4.6 Tires, Maintaining........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3519
1.4.7 Tire, Uniformly Worn......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3520
1.4.8 Tread Depth, Measuring....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3520
1.4.9 Tire Wear, One Sided......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3521
1.4.10 Tire Wear, Outer Shoulder................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3524
1.4.11 Tire Wear, Center........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3524
1.4.12 Diagonal Washouts........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3526
1.5 Tires, Rolling Noises...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3526
1.5.1 Rolling Noises............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3526
1.5.2 Heel and Toe Wear.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3527
1.5.3 Wear Spots................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3528
1.6 Wheel and Tire Vibration........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3529
1.6.1 Causes for Vibration......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3529
1.6.2 Balancing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3530
1.6.3 Road Test, Performing before Balancing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................3530
1.6.4 Stationary Balancing Machine..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3530
1.6.5 Vibration Control Tire Balancer VAS 6230..................................................................................................................................................................................................................................................................................................................................................................................................................................................................3532
1.6.6 Finish Balancer...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3532
1.6.7 Wheels and Tires, Radial Lateral Run-Out..................................................................................................................................................................................................................................................................................................................................................................................................................................................................3533
1.6.8 Wheel and Tire Radial and Lateral Run-Out, Checking with Tire Dial Gauge..................................................................................................................................................................................................................................................................................................................................................................................................................................3534
1.6.9 Disc Wheel, Checking Radial and Lateral Run-Out...........................................................................................................................................................................................................................................................................................................................................................................................................................................................3534
1.6.10 Matched Mounting.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3535
1.6.11 Flat Spots in Tires from Standing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3536
1.7 Vehicle Pulls to One Side.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3538
1.7.1 General Information.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3538
1.7.2 Taper.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3538
1.7.3 Corrective Action When Vehicle Pulls to One Side..........................................................................................................................................................................................................................................................................................................................................................................................................................................................3539
1.7.4 Targeted Rotating of Wheels for Non-Directional Tires.....................................................................................................................................................................................................................................................................................................................................................................................................................................................3540
1.7.5 Wheels, Targeted Rotating for Directional Tires...........................................................................................................................................................................................................................................................................................................................................................................................................................................................3541
1.8 Tire Damage.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3542
1.8.1 General Information.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3542
1.8.2 Radial Tires, Construction................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3543
1.8.3 Impact Damage.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3543
1.8.4 Cuts......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3545
1.8.5 Damage from Foreign Bodies................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3545
1.8.6 Air Loss..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3545
1.8.7 Tire Pressure.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3545
1.8.8 Damage from Low Tire Pressure.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3546
1.8.9 Tire Temperature, Rising When Tires Pressure Is Too Low...................................................................................................................................................................................................................................................................................................................................................................................................................................................3547
1.8.10 Damage Due to Mounting Error, Damage from Fitting the Tire...............................................................................................................................................................................................................................................................................................................................................................................................................................................3548
1.9 Tires with Emergency Running Characteristics....................................................................................................................................................................................................................................................................................................................................................................................................................................................................3549
1.9.1 General Information.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3549
1.9.2 Structure and Identification..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3550
1.9.3 Installing/Conditions for Using Run-Flat Tires............................................................................................................................................................................................................................................................................................................................................................................................................................................................3551
1.9.4 Repairing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3552
1.10 Rolling Resistance Tires.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3552
1.11 Disc Wheels....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3553
1.11.1 Disc Wheel Structure.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3553
1.11.2 Disc Wheels, Identification..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3554
1.11.3 Disc Wheels Rims, Pitch Circle Diameter..................................................................................................................................................................................................................................................................................................................................................................................................................................................................3554
1.11.4 Multipart Composite Wheels...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3554
1.11.5 Light Alloy Wheels, Replacement Decoration Elements......................................................................................................................................................................................................................................................................................................................................................................................................................................................3555
1.11.6 Light Alloy Wheels, Replacement Decoration Elements (Zaragoza)...........................................................................................................................................................................................................................................................................................................................................................................................................................................3555
1.11.7 Light Alloy Wheels, Care and Maintenance.................................................................................................................................................................................................................................................................................................................................................................................................................................................................3558
1.11.8 Light Alloy Wheels, Preparing............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3559
1.12 Wheels, Mounting...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3560
1.12.1 Rotating.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3560
1.12.2 Changing and Mounting....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3561
1.12.3 Emergency Wheels, Using..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3562
1.13 Wheel Repair Kit...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3563
1.14 Spare Tires and Emergency Wheels...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3563
1.15 Recommended Summer Tires.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3564
1.15.1 Beetle from MY 12........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3565
1.15.2 New Beetle Cabriolet, from MY 2003.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3565
1.15.3 Golf, from MY 2009.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3566
1.15.4 GTI, from MY 2009........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3567
1.15.5 Golf R, from MY 10.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3568
1.15.6 Jetta Wagon, from MY 2010................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3568
1.15.7 Jetta, from MY 2006......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3569
1.15.8 Tiguan, from MY 2008.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3571
1.15.9 Eos, from MY 2006........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3571
1.15.10 Passat Sedan, from MY 2006..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3572
1.15.11 Passat Wagon, from MY 2006..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3573
1.15.12 Passat CC, from MY 2009.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3574
1.15.13 Phaeton, from MY 2003...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3574
1.15.14 Touareg, from MY 2010...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3575
1.15.15 Touareg Hybrid, from MY 11..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3575
1.16 Recommended All Season Tires...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3576
1.16.1 Beetle from MY 12........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3576
1.16.2 New Beetle Cabriolet, from MY 2003.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3577
1.16.3 Golf, from MY 2009.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3577
1.16.4 Jetta Wagon, from MY 2010................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3577
1.16.5 Jetta, from MY 2006......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3578
1.16.6 Jetta, MY 11.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3578
1.16.7 Tiguan, from MY 2008.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3579
1.16.8 Eos, from MY 2006........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3579
1.16.9 Passat Sedan, from MY 2006...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3579
1.16.10 Passat Wagon, from MY 2006..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3580
1.16.11 Passat CC, from MY 2009.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3580
1.16.12 Phaeton, from MY 2003...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3580
1.16.13 Touareg, from MY 2010...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3580
1.17 Recommended Winter Tires.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3581
1.17.1 Beetle from MY 12........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3582
1.17.2 New Beetle Cabriolet, from MY 2003.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3582
1.17.3 Golf, from MY 2009.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3582
1.17.4 GTI, from MY 2009........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3583
1.17.5 Golf R, from MY 10.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3583
1.17.6 Jetta Wagon, from MY 2010................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3583
1.17.7 Jetta, from MY 2006......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3583
1.17.8 Tiguan, from MY 2008.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3584
1.17.9 Eos, from MY 2006........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3584
1.17.10 Passat Sedan, from MY 2006..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3584
1.17.11 Passat Wagon, from MY 2006..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3585
1.17.12 Passat CC, from MY 2009.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3586
1.17.13 Phaeton, from MY 2003...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3586
1.17.14 Touareg, from MY 2010...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3586
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3588
2.1 Side Wall Lettering.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3588
2.2 Tire Lettering Explanation......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3589
2.3 Tires, Speed Ratings............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3591
2.4 Cracking........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3592
2.5 Tires, Storing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3592
2.6 Tires, Aging....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3593
2.7 Tire Sizes, AWD Vehicles........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3594
2.8 Winter Tires....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3594
2.9 Winter Tires with Speed Rating V................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3595
2.10 Winter Tires, Extra Load, Speed Rating V.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3596
2.11 Winter Tires, Maximum Speeds for V and Extra Load..............................................................................................................................................................................................................................................................................................................................................................................................................................................................3596
2.12 Tires, Reinforced, Extra Load..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3597
2.13 Snow Chains....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3598
3 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3599
3.1 Golf, from MY 2009..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3599
3.1.1 Golf and Golf 4MOTION Sales Type 5K, MY 2009 through MY 2011..............................................................................................................................................................................................................................................................................................................................................................................................................................................3600
3.1.2 Golf and Golf 4MOTION Sales Type 5K MY 2009 through MY 2011 Wheel Allocation..............................................................................................................................................................................................................................................................................................................................................................................................................................3605
3.1.3 6 J x 15..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3605
3.1.4 61/2 J x 15...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3606
3.1.5 6 J x 16..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3607
3.1.6 61/2 J x 16...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3608
3.1.7 6 J x 17..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3613
3.1.8 7 J x 17..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3613
3.1.9 71/2 J x 17...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3617
3.1.10 71/2 J x 18..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3619
3.2 Golf GTI, from MY 2010..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3622
3.2.1 Golf GTI, Sales Type 5K, from MY 2010 through MY 2011.....................................................................................................................................................................................................................................................................................................................................................................................................................................................3623
3.2.2 Wheel Assignment, Golf GTI, Type 5K, from MY 2010 through MY 2011.........................................................................................................................................................................................................................................................................................................................................................................................................................................3624
3.2.3 6 J x 16..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3624
3.2.4 61/2 J x 16...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3625
3.2.5 6 J x 17..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3630
3.2.6 7 J x 17..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3630
3.2.7 71/2 J x 17...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3634
3.2.8 71/2 J x 18...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3636
3.3 Golf R, from MY 10..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3639
3.3.1 Golf R Sales Type 5K, MY 10...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3640
3.3.2 Golf R Sales Type 5K, MY 11...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3641
3.3.3 Wheel Assignment, Golf R, Type 5K, from MY 10 through MY 11...............................................................................................................................................................................................................................................................................................................................................................................................................................................3643
3.3.4 6 J x 17..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3643
3.3.5 7 J x 17..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3643
3.3.6 71/2 J x 17...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3644
3.3.7 71/2 J x 18...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3645
3.3.8 8 J x 19..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3648
3.4 Jetta Wagon, from MY 2010.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3649
3.4.1 Golf Wagon, Golf Wagon 4MOTION; SalesType AJ5, MY 10 through MY 11........................................................................................................................................................................................................................................................................................................................................................................................................................................3650
3.4.2 Wheel Allocation, Golf Wagon, Golf Wagon 4MOTION; SalesType AJ5, MY 10 through MY 11......................................................................................................................................................................................................................................................................................................................................................................................................................3659
3.4.3 6 J x 15..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3659
3.4.4 61/2 J x 15...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3660
3.4.5 6 J x 16..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3661
3.4.6 61/2 J x 16...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3662
3.4.7 6 J x 17..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3667
3.4.8 7 J x 17..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3667
3.4.9 71/2 J x 17...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3671
3.4.10 71/2 J x 18..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3673
3.5 Jetta, from MY 2006.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3676
3.5.1 Jetta, Type 1KM, MY 2006..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3677
3.5.2 Jetta, Type 1KM, MY 2007 through MY 2008..................................................................................................................................................................................................................................................................................................................................................................................................................................................................3680
3.5.3 Jetta, Type 1KM, MY 2009 through MY 2011..................................................................................................................................................................................................................................................................................................................................................................................................................................................................3684
3.5.4 Wheel Assignment, Jetta, Type 1KM, MY 2006 through MY 2011................................................................................................................................................................................................................................................................................................................................................................................................................................................3695
3.5.5 6 J x 15..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3695
3.5.6 61/2 J x 15...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3696
3.5.7 6 J x 16..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3697
3.5.8 61/2 J x 16...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3698
3.5.9 7 J x 17..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3703
3.5.10 71/2 J x 17..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3706
3.5.11 71/2 J x 18..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3708
3.6 Jetta, from MY 11...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3711
3.6.1 Jetta, Sales Type 162, MY 11..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3712
3.6.2 Wheel Allocation, Jetta, Sales Type 162, MY 11............................................................................................................................................................................................................................................................................................................................................................................................................................................................3714
3.6.3 6 J x 15..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3714
3.6.4 61/2 J x 15...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3715
3.6.5 6 J x 16..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3716
3.6.6 61/2 J x 16...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3717
3.6.7 7 J x 17..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3722
3.7 Beetle from MY 12...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3726
3.7.1 Beetle, Sales Type 5C1, from MY 12........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3727
3.7.2 Beetle, Sales Type 5C1, from MY 12........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3728
3.7.3 61/2 J x 16...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3728
3.7.4 7 J x 17..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3729
3.7.5 8 J x 18..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3731
3.7.6 8 J x 19..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3731
3.8 New Beetle Cabriolet, from MY 2003..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3732
3.8.1 New Beetle Cabriolet, Type 1Y, MY 2003 through MY 2010....................................................................................................................................................................................................................................................................................................................................................................................................................................................3733
3.8.2 Wheel Assignment, New Beetle Cabriolet, Type 1Y, MY 2003 through MY 2010..................................................................................................................................................................................................................................................................................................................................................................................................................................3736
3.8.3 6 J x 15..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3736
3.8.4 51/2 J x 16...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3738
3.8.5 61/2 J x 16...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3739
3.8.6 7 J x 17..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3744
3.8.7 71/2 J x 17...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3747
3.8.8 17" Wheels and Tires, Conditions for Mounting.............................................................................................................................................................................................................................................................................................................................................................................................................................................................3747
3.9 Tiguan, from MY 2008............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3748
3.9.1 Tiguan, Type 5N, MY 2008 through MY 2011..................................................................................................................................................................................................................................................................................................................................................................................................................................................................3749
3.9.2 Tiguan Wheel Allocation, Type 5N, MY 2008 through MY 2011.................................................................................................................................................................................................................................................................................................................................................................................................................................................3750
3.9.3 6 1/2 J x 16..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3750
3.9.4 61/2 J x 17...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3751
3.9.5 7 J x 17..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3751
3.9.6 7 J x 18..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3752
3.9.7 9 J x 19..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3753
3.10 Eos, from MY 2006..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3754
3.10.1 Eos, Type 1F, MY 2006....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3754
3.10.2 Eos, Type 1F, MY 2007 through MY 2010....................................................................................................................................................................................................................................................................................................................................................................................................................................................................3757
3.10.3 Eos Wheel Allocation, Type 1F MY 2006 through MY 2010....................................................................................................................................................................................................................................................................................................................................................................................................................................................3760
3.10.4 61/2 J x 16..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3761
3.10.5 7 J x 16.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3761
3.10.6 6 J x 17.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3763
3.10.7 71/2 J x 17..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3763
3.10.8 8 J x 18.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3765
3.11 Passat CC, from MY 2009........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3767
3.11.1 Passat CC, Sales Type 357, MY 2009.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3768
3.11.2 Passat CC, Sales Type 357, MY 10 through MY 11...........................................................................................................................................................................................................................................................................................................................................................................................................................................................3770
3.11.3 Passat CC Wheel Allocation, Sales Type 357, Model Year 2009 through 2011.................................................................................................................................................................................................................................................................................................................................................................................................................................3771
3.11.4 61/2 J x 17..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3772
3.11.5 8 J x 17.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3772
3.11.6 8 J x 18.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3773
3.11.7 8 J x 19.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3774
3.12 Phaeton, from MY 2003..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3775
3.12.1 Phaeton, Type 3D, MY 2003 through MY 2009, Short and Long Wheel Base.....................................................................................................................................................................................................................................................................................................................................................................................................................................3776
3.12.2 Phaeton, Type 3D and Type 3d, MY 10 through MY 11, Short and Long Wheel Base.............................................................................................................................................................................................................................................................................................................................................................................................................................3779
3.12.3 Wheel Allocation, Phaeton, Type 3D and Type 3d, MY 10 through MY 11, Short and Long Wheel Base...........................................................................................................................................................................................................................................................................................................................................................................................................3782
3.12.4 71/2 J x 16..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3782
3.12.5 71/2 J x 17..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3783
3.12.6 71/2 J x 18..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3784
3.12.7 81/2 J x 18..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3785
3.12.8 81/2 J x 19 ET 38........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3787
3.12.9 81/2 J x 19 ET 45........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3787
3.12.10 9 J€x€19 ET€35..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3788
3.12.11 9 J€x€19 ET€40..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3788
3.13 Touareg, from MY 2010..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3789
3.13.1 Touareg, Type 7P and Type 7p, MY 10 through MY 11........................................................................................................................................................................................................................................................................................................................................................................................................................................................3790
3.13.2 Wheel Allocation, Touareg, Type 7P and Type 7p, MY 10 through MY 11......................................................................................................................................................................................................................................................................................................................................................................................................................................3792
3.13.3 71/2 J x 17..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3792
3.13.4 8 J x 18.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3792
3.13.5 81/2 J x 19..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3793
3.13.6 9 J x 20.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3794
3.13.7 91/2 J x 21..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3795
3.14 Touareg Hybrid, from MY 11.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3795
3.14.1 Touareg Hybrid, Type 7PH and Type 7pH, MY 11.............................................................................................................................................................................................................................................................................................................................................................................................................................................................3796
3.14.2 Wheel Allocation, Touareg Hybrid, Type 7PH and Type 7pH, MY 11...........................................................................................................................................................................................................................................................................................................................................................................................................................................3797
3.14.3 8 J x 18.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3797
3.14.4 81/2 J x 19..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3798
4 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3800
05-04 Wheel and Tire Guide 2013.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3804
44 – Wheels, Tires, Wheel Alignment.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3808
1 Wheel and Tire Combinations...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3808
1.1 General Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3808
1.2 Golf, MY 2009 through MY 2012, Sales Code 5K....................................................................................................................................................................................................................................................................................................................................................................................................................................................................3808
1.3 Golf BlueMotion, MY 2009 through MY 2013, Sales Code 5K.........................................................................................................................................................................................................................................................................................................................................................................................................................................................3813
1.4 Golf GTD, MY 2010 through MY 2012, Sales Code 5K................................................................................................................................................................................................................................................................................................................................................................................................................................................................3818
1.5 Golf GTI, MY 2010 through MY 2012, Sales Code 5K................................................................................................................................................................................................................................................................................................................................................................................................................................................................3820
1.6 Golf R, MY 12, Sales Code 5K....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3825
1.7 Golf R, MY 2011 through MY 2012, Sales Code 5K..................................................................................................................................................................................................................................................................................................................................................................................................................................................................3826
2 Wheel Allocation......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3830
2.1 6 J x 15........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3830
2.2 61/2 J x 15.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3831
2.3 6 J x 16........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3832
2.4 61/2 J x 16.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3833
2.5 6 J x 17........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3837
2.6 7 J x 17 ET 47..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3837
2.7 7 J x 17 ET 54..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3838
2.8 71/2 J x 17.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3841
2.9 71/2 J x 18.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3842
2.10 71/2 J x 19....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3845
2.11 8 J x 19.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3847
3 Recommended Summer Tires..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3848
4 Recommended All Season Tires..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3850
5 Recommended Winter Tires..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3851
6 Recommended Spare Tires and Emergency Wheels..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3852
7 Revision History......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3854
06-Brake System.pdf (p.3858-3996)...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3858
00 – General, Technical Data....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3862
1 General Information.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3862
1.1 Brake PR Number, Allocating.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3862
1.2 General Information.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3864
2 Specifications............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3865
2.1 Front Brakes........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3865
2.2 Rear Brakes.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3867
2.3 Brake Master Cylinder and Brake Booster.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3869
3 Diagnosis and Testing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3870
3.1 Brake Testing with FWD..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3870
3.2 Brake Testing with AWD, Testing Via Haldex Clutch...................................................................................................................................................................................................................................................................................................................................................................................................................................................................3870
45 – Antilock Brake System......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3871
1 General Information.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3871
1.1 Antilock Brake System (ABS).........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3871
1.2 Antilock Brake System (ABS) Repair Information......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3872
1.3 Electronic Stabilization Program Components.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3872
2 Description and Operation.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3874
2.1 Front Wheel Speed Sensor Overview...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3874
2.2 Rear Wheel Speed Sensor Overview....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3875
2.3 ABS Mark 70 (ABS/ASR)...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3876
2.3.1 Electrical and Electronic Components and Component Locations..................................................................................................................................................................................................................................................................................................................................................................................................................................................3876
2.3.2 Hydraulic Unit and Brake Booster/Master Cylinder Overview.....................................................................................................................................................................................................................................................................................................................................................................................................................................................3878
2.3.3 Brake Lines Connecting to Master Cylinder and Hydraulic Unit..................................................................................................................................................................................................................................................................................................................................................................................................................................................3879
2.4 ABS Mark 60 EC (ABS/EDL/ASR/ESP)....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3881
2.4.1 Electrical and Electronic Components and Component Locations..................................................................................................................................................................................................................................................................................................................................................................................................................................................3881
2.4.2 Hydraulic Unit and Brake Booster/Master Cylinder Overview.....................................................................................................................................................................................................................................................................................................................................................................................................................................................3883
2.4.3 Brake Lines Connecting to Master Cylinder and Hydraulic Unit..................................................................................................................................................................................................................................................................................................................................................................................................................................................3884
2.5 Level Control System Indicator Lamps................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3885
2.6 -VAS€5051- Connecting and Selection Functions.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3886
3 Specifications............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3888
3.1 Fastener Tightening Specifications..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3888
4 Removal and Installation..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3889
4.1 Control Module and Hydraulic Unit (ABS Mark 70 (ABS/ASR))...........................................................................................................................................................................................................................................................................................................................................................................................................................................................3889
4.2 Control Module and Hydraulic Unit (ABS Mark 60 EC (ABS/EDL/ASR/ESP))................................................................................................................................................................................................................................................................................................................................................................................................................................................3892
4.3 Steering Angle Sensor -G85-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3895
4.4 Rear ABS Wheel Speed Sensors G44/G46................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3895
4.5 Front ABS Wheel Speed Sensors G45/G47...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3895
5 Disassembly and Assembly..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3896
5.1 Removing Control Module from Hydraulic Unit (ABS Mark 70 (ABS/ASR)..................................................................................................................................................................................................................................................................................................................................................................................................................................................3896
5.2 Removing Control Module from Hydraulic Unit (ABS Mark 60 EC (ABS/EDL/ASR/ESP))......................................................................................................................................................................................................................................................................................................................................................................................................................................3897
6 Special Tools.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3899
46 – Mechanical Components......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3900
1 Description and Operation.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3900
1.1 Front Brakes........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3900
1.1.1 Front Brakes Overview, FS III.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3900
1.1.2 Front Brakes Overview, FN 3...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3902
1.1.3 Front Brakes Overview, FNR-G..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3905
1.2 Rear Brakes.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3907
1.2.1 Rear Brakes Overview, C 38....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3907
1.2.2 Rear Brakes Overview, CII 41..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3909
1.2.3 Rear Brakes Overview, Bosch...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3913
1.3 Parking Brake Lever Overview........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3915
1.4 Brake Pedal Overview................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3915
1.5 Parking Brake, Adjusting............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3916
2 Specifications............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3918
2.1 Fastener Tightening Specifications..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3918
3 Removal and Installation..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3919
3.1 Front Brakes........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3919
3.1.1 Front Brakes Pads, FNR-G......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3919
3.1.2 Front Brake Caliper, FNR-G....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3922
3.1.3 Front Brake Pads, FN 3........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3927
3.1.4 Front Brake Caliper, FN 3.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3930
3.1.5 Front Brake Pads, FS III......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3931
3.1.6 Front Brake Caliper, FS III...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3933
3.2 Rear Brakes.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3935
3.2.1 Rear Brake Pads, Bosch........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3935
3.2.2 Rear Brake Caliper, Bosch.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3937
3.2.3 Rear Brake Pads, CII 41.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3939
3.2.4 Rear Brake Caliper, CII 41....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3941
3.2.5 Rear Brake Pads, C 38.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3944
3.2.6 Rear Brake Caliper, C 38......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3946
3.3 Parking Brake Cable.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3947
3.4 Brake Pedal Mounting Bracket........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3949
3.5 Brake Pedal.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3950
3.6 Brake Pedal, Separating from Brake Booster..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3950
4 Special Tools.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3952
47 – Hydraulic Components.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3954
1 General Information.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3954
1.1 Brake Caliper, Pre-Bleeding.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3954
1.2 Brake System, Bleeding..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3954
1.3 Brake Fluid, Changing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3956
2 Description and Operation.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3957
2.1 Front Brakes........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3957
2.1.1 Front Brake Caliper Overview, FS III..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3957
2.1.2 Front Brake Caliper Overview, FN 3............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3958
2.1.3 Front Brake Caliper Overview, FNR-G...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3960
2.2 Rear Brakes.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3961
2.2.1 Rear Brake Caliper Overview, C38..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3961
2.2.2 Brake Caliper Overview, CII 41................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3962
2.2.3 Rear Brake Caliper Overview, Bosch............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3964
2.3 Brake Lines.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3966
2.3.2 Brake Lines, Repairing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3966
2.4 Brake Booster and Master Cylinder Overview..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................3970
2.5 Brake Booster Vacuum Pump, Diesel...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3972
2.6 Brake Booster Vacuum Pump, 2.0L Gasoline............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3973
3 Specifications............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3974
3.1 Fastener Tightening Specifications..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3974
4 Diagnosis and Testing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3975
4.1 Brake Booster Vacuum System, Checking...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3975
4.2 Check Valve, Checking...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3979
4.3 Leakage Test Under Pressure.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3979
5 Removal and Installation..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3980
5.1 Front Brakes........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3980
5.1.1 Front Brake Caliper Piston, FS III............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3980
5.1.2 Front Brake Caliper Piston, FN 3..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3981
5.1.3 Front Brake Caliper Piston, FNR-G.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................3983
5.2 Rear Brakes.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3985
5.2.1 Rear Brake Caliper Piston, C 38 and CII 41....................................................................................................................................................................................................................................................................................................................................................................................................................................................................3985
5.2.2 Brake Caliper Piston, Bosch...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3987
5.3 Vacuum Sensor -G608-................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3988
5.4 Brake Booster Pressure Sensor -G294-................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3989
5.5 Brake System Vacuum Pump -V192-.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3989
5.6 Brake Lamp Switch -F-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3990
5.7 Master Brake Cylinder...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3990
5.8 Brake Booster.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3991
6 Special Tools.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................3994
07-Heating Ventilation and Air Conditioning.pdf (p.3997-4173).......................................................................................................................................................................................................................................................................................................................................................................................................................................................................3997
00 – General, Technical Data....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4003
1 General Information.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4003
1.1 Safety Precautions when Working on Air Conditioning Systems Safety Precautions......................................................................................................................................................................................................................................................................................................................................................................................................................................4003
1.2 Safety Precautions when Working on the High Voltage System..........................................................................................................................................................................................................................................................................................................................................................................................................................................................4004
1.3 Safety Precautions when Working near High Voltage Components........................................................................................................................................................................................................................................................................................................................................................................................................................................................4005
1.4 Safety Precautions when Working on Start/Stop System................................................................................................................................................................................................................................................................................................................................................................................................................................................................4005
1.5 Safety Precautions when Working on Cooling System...................................................................................................................................................................................................................................................................................................................................................................................................................................................................4005
1.6 Odors in Vehicles with A/C System...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4005
1.7 Vehicles with Start/Stop System General Information.................................................................................................................................................................................................................................................................................................................................................................................................................................................................4006
1.8 Working on the Refrigerant Circuit..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4006
1.9 Refrigerant Circuit Seals...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4006
1.10 Actuator Information...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4007
1.10.1 Actuator Information.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4007
1.10.2 Connecting Element, Inserting in Actuator Shaft..............................................................................................................................................................................................................................................................................................................................................................................................................................................................4009
1.10.3 Actuator, Activating using Adapter Cable.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4011
1.10.4 Adapter Cable for Activating Actuators.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................4012
1.11 Refrigerant R134a Capacities.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4012
1.12 Refrigerant Oil....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4012
1.13 Oil Distribution...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4012
80 – Heating, Ventilation.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4013
1 Diagnosis and Testing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4013
1.1 Auxiliary Heater Heating Element -Z35-, Checking....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4013
1.2 Vehicle Interior Forced Air Extraction, Checking....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4013
2 Removal and Installation..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4014
2.1 Fresh Air Blower -V2-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4014
2.2 Fresh Air Blower Series Resistor with Fuse -N24-....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4014
2.3 Dust and Pollen Filter..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4014
2.4 Auxiliary Heater Heating Element -Z35-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4014
2.5 Heater Core.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4014
2.6 Center Vent.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4014
2.7 Driver Side or Front Passenger Side Vent............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4014
2.8 Driver Side Footwell Vent...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4015
2.9 Front Passenger Side Footwell Vent..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4015
2.10 Rear Channel, Footwell.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4015
2.11 Fresh Air Intake...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4015
2.12 Vehicle Interior Forced Air Extraction.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4015
2.13 Air Intake Housing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4015
2.14 Heater Core Coolant Pipes..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4015
87 – Air Conditioning...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4016
1 Description and Operation.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4016
1.1 Overview - Components in Front Vehicle Interior.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4016
1.1.1 Overview - Components Inside Front Passenger Compartment, Climatic through 05/27/2011.........................................................................................................................................................................................................................................................................................................................................................................................................................4016
1.1.2 Overview - Components Inside Front Passenger Compartment, Manual A/C System from 05/30/ 2011..................................................................................................................................................................................................................................................................................................................................................................................................................4019
1.1.3 Overview - Front Components Inside Passenger Compartment, Climatronic.........................................................................................................................................................................................................................................................................................................................................................................................................................................4019
1.1.4 Components Inside Front Passenger Compartment Component Location Overview, Climatic through 05/27/2011, Right-Hand Drive Vehicles.............................................................................................................................................................................................................................................................................................................................................................................4022
1.1.5 Components Inside Front Passenger Compartment Component Location Overview, Manual A/C System from 30 May 2011, Right-Hand Drive Vehicle.......................................................................................................................................................................................................................................................................................................................................................................4024
1.1.6 Front Components Inside Passenger Compartment Component Location Overview, Climatronic, Right-Hand Drive Vehicle..............................................................................................................................................................................................................................................................................................................................................................................................4025
1.2 Overview - Refrigerant Circuit......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4027
1.2.1 Overview - Refrigerant Circuit, MY 2009.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................4027
1.2.2 Refrigerant Circuit System Overview, Golf Blue eMotion, Front.................................................................................................................................................................................................................................................................................................................................................................................................................................................4028
1.2.3 System Overview - Refrigerant Circuit, Golf Blue-e-Motion, Rear...............................................................................................................................................................................................................................................................................................................................................................................................................................................4029
1.3 Overview - A/C Compressor Power Unit................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4031
1.4 Overview - Heater and A/C Unit......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4033
1.4.1 Overview - Heater and A/C Unit, Climatic......................................................................................................................................................................................................................................................................................................................................................................................................................................................................4033
1.4.2 Overview - Heater and A/C Unit, Manual Climate Control System.................................................................................................................................................................................................................................................................................................................................................................................................................................................4035
1.4.3 Overview - Heater and A/C Unit, Climatronic...................................................................................................................................................................................................................................................................................................................................................................................................................................................................4037
1.4.4 Heater and A/C Unit Assembly Overview, Climatic, Right-Hand Drive Vehicle.....................................................................................................................................................................................................................................................................................................................................................................................................................................4039
1.4.5 Heater and A/C Unit Assembly Overview, Manual Climate Control System, Right-Hand Drive Vehicle................................................................................................................................................................................................................................................................................................................................................................................................................4041
1.4.6 Heater and A/C Unit Assembly Overview, Climatronic, Right-Hand Drive Vehicle..................................................................................................................................................................................................................................................................................................................................................................................................................................4043
1.5 Overview - Evaporator Housing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4045
1.5.1 Overview - Evaporator Housing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4045
1.5.2 Evaporator Housing Assembly Overview, Right-Hand Drive Vehicle................................................................................................................................................................................................................................................................................................................................................................................................................................................4046
1.6 Overview - Coolant Circuit, Golf Blue-e-Motion......................................................................................................................................................................................................................................................................................................................................................................................................................................................................4047
1.6.1 Coolant Circuit Assembly Overview, Golf Blue eMotion, Front...................................................................................................................................................................................................................................................................................................................................................................................................................................................4047
1.6.2 Coolant Circuit Assembly Overview, Golf Blue eMotion, Rear....................................................................................................................................................................................................................................................................................................................................................................................................................................................4048
1.7 Overview - Display Control Head.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4049
1.7.1 Overview - Display Control Head, Climatic through 05/27/2011..................................................................................................................................................................................................................................................................................................................................................................................................................................................4049
1.7.2 Overview - Display Control Head, Electric Manual Climate Control System from 05/29/2011.......................................................................................................................................................................................................................................................................................................................................................................................................................4051
1.7.3 Overview - Display Control Head, Climatronic through 05/25/2012...............................................................................................................................................................................................................................................................................................................................................................................................................................................4053
1.7.4 Overview - Display Control Head, Climatronic from 05/28/2012..................................................................................................................................................................................................................................................................................................................................................................................................................................................4055
1.8 Overview - Front Adjustment Motors..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4057
1.8.1 Overview - Front Adjustment Motor, Climatic, through 05/27/2011...............................................................................................................................................................................................................................................................................................................................................................................................................................................4057
1.8.2 Overview - Front Actuators, Climatronic.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................4058
1.8.3 Front Adjustment Motor Component Location Overview, Climatic, Right-Hand Drive Vehicles through 05/27/2011....................................................................................................................................................................................................................................................................................................................................................................................................4059
1.8.4 Component Location Overview - Front Motors, Electric-Manual Climate Control System, RHD, from 05/30/2011......................................................................................................................................................................................................................................................................................................................................................................................................4059
1.8.5 Component Location Overview - Front Actuators, Climatronic, RHD...............................................................................................................................................................................................................................................................................................................................................................................................................................................4060
1.9 Air Quality Sensor -G238- Function..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4061
2 Diagnosis and Testing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4063
2.1 Pressure Relief Valve on A/C Compressor, Checking...................................................................................................................................................................................................................................................................................................................................................................................................................................................................4063
2.2 Condensation Water Drain, Checking..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4063
2.2.1 Condensation Water Drain, Checking............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4063
2.2.2 Condensation Water Drain, Checking, RHD.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................4064
2.3 Vehicle Interior Forced Air Extraction, Checking....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4065
2.4 Auxiliary Heater Heating Element -Z35-, Checking....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4065
2.4.1 Auxiliary Heater Heating Element -Z35-, Checking..............................................................................................................................................................................................................................................................................................................................................................................................................................................................4065
2.4.2 Auxiliary Heater Heating Element -Z35-, Checking, RHD.........................................................................................................................................................................................................................................................................................................................................................................................................................................................4066
3 Removal and Installation..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4069
3.1 High Pressure Sensor -G65-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4070
3.1.1 High Pressure Sensor -G65-, Removing and Installing, Gasoline Engine..........................................................................................................................................................................................................................................................................................................................................................................................................................................4071
3.1.2 High Pressure Sensor -G65-, Removing and Installing, Common Rail Diesel.......................................................................................................................................................................................................................................................................................................................................................................................................................................4072
3.2 Expansion Valve.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4073
3.2.1 Expansion Valve, Removing and Installing, MY 2009.............................................................................................................................................................................................................................................................................................................................................................................................................................................................4073
3.2.2 Expansion Valve, Removing and Installing, Golf Blue-e-Motion..................................................................................................................................................................................................................................................................................................................................................................................................................................................4075
3.3 Condenser...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4077
3.4 Receiver/Dryer......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4079
3.4.1 Receiver/Dryer, Removing and Installing, Showa................................................................................................................................................................................................................................................................................................................................................................................................................................................................4079
3.5 Dryer Bag/Dryer Cartridge...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4081
3.5.1 Dryer Bag/Dryer Cartridge, Removing and Installing, Modine....................................................................................................................................................................................................................................................................................................................................................................................................................................................4081
3.6 Evacuating and Charging Valve, Low and High Pressure Side...........................................................................................................................................................................................................................................................................................................................................................................................................................................................4083
3.7 High Voltage Battery Heat Exchanger -VX63-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4084
3.8 Heater and A/C Unit Refrigerant Cut-Off Valve -N541-................................................................................................................................................................................................................................................................................................................................................................................................................................................................4086
3.9 High Voltage Battery Heater Core Refrigerant Cut-Off Valve -N542-...................................................................................................................................................................................................................................................................................................................................................................................................................................................4087
3.10 A/C Compressor at Bracket..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4088
3.11 A/C Compressor.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4090
3.11.1 A/C Compressor, Removing and Installing, MY 2009.............................................................................................................................................................................................................................................................................................................................................................................................................................................................4090
3.11.2 A/C Compressor, Removing and Installing, Golf Blue-e-Motion..................................................................................................................................................................................................................................................................................................................................................................................................................................................4093
3.12 Belt Pulley........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4096
3.12.1 Belt Pulley, Removing and Installing, Denso..................................................................................................................................................................................................................................................................................................................................................................................................................................................................4096
3.13 Heater and A/C Unit................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4098
3.13.1 Heater and A/C Unit, Removing and Installing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................4098
3.13.2 Heating and A/C Unit, Removing and Installing, Right-Hand Drive Vehicle......................................................................................................................................................................................................................................................................................................................................................................................................................................4102
3.14 Evaporator.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4106
3.15 Fresh Air Blower Series Resistor with Fuse -N24-...................................................................................................................................................................................................................................................................................................................................................................................................................................................................4107
3.16 Fresh Air Blower Control Module -J126-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4107
3.16.1 Fresh Air Blower Control Module -J126-, Removing and Installing..............................................................................................................................................................................................................................................................................................................................................................................................................................................4107
3.16.2 Fresh Air Blower Control Module -J126-, Removing and Installing, RHD.........................................................................................................................................................................................................................................................................................................................................................................................................................................4108
3.17 Dust and Pollen Filter.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4108
3.17.1 Dust and Pollen Filter, Removing and Installing..............................................................................................................................................................................................................................................................................................................................................................................................................................................................4108
3.17.2 Dust and Pollen Filter, Removing and Installing, RHD.........................................................................................................................................................................................................................................................................................................................................................................................................................................................4109
3.18 Fresh Air Blower -V2-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4110
3.18.1 Fresh Air Blower -V2-, Removing and Installing, A/C System with Manual Controls..............................................................................................................................................................................................................................................................................................................................................................................................................................4110
3.18.2 Fresh Air Blower -V2-, Removing and Installing, Climatronic..................................................................................................................................................................................................................................................................................................................................................................................................................................................4110
3.18.3 Fresh Air Blower -V2-, Removing and Installing, A/C System with Manual Controls, RHD.........................................................................................................................................................................................................................................................................................................................................................................................................................4111
3.18.4 Fresh Air Blower -V2-, Removing and Installing, Climatronic, RHD.............................................................................................................................................................................................................................................................................................................................................................................................................................................4112
3.19 Auxiliary Heater Heating Element -Z35-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4112
3.19.1 Auxiliary Heater Heating Element -Z35-, Removing and Installing..............................................................................................................................................................................................................................................................................................................................................................................................................................................4112
3.19.2 Auxiliary Heater Heating Element -Z35-, Removing and Installing, RHD.........................................................................................................................................................................................................................................................................................................................................................................................................................................4113
3.20 Heater Core........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4116
3.20.1 Heater Core, Removing and Installing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4116
3.20.2 Heater Core, Removing and Installing, RHD....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4119
3.21 Evaporator Temperature Sensor -G308-/Evaporator Vent Temperature Sensor -G263-.....................................................................................................................................................................................................................................................................................................................................................................................................................................4123
3.21.1 Evaporator Temperature Sensor -G308-/Evaporator Vent Temperature Sensor -G263-, Removing and Installing......................................................................................................................................................................................................................................................................................................................................................................................................4123
3.21.2 Evaporator Vent Temperature Sensor -G263- or Evaporator Temperature Sensor -G308-, Removing and Installing, RHD..............................................................................................................................................................................................................................................................................................................................................................................................4124
3.22 Center Vent........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4124
3.23 Driver Side or Front Passenger Side Vent...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4125
3.24 Rear Channel, Footwell.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4125
3.25 Air Distribution Housing...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4126
3.25.1 Air Distribution Housing, Removing and Installing............................................................................................................................................................................................................................................................................................................................................................................................................................................................4126
3.25.2 Air Distribution Housing, Removing and Installing, Right-Hand Drive Vehicle..................................................................................................................................................................................................................................................................................................................................................................................................................................4127
3.26 Air Intake Housing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4129
3.26.1 Air Intake Housing, Removing and Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................4129
3.27 Fresh Air Intake...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4130
3.27.1 Fresh Air Intake, Removing and Installing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4130
3.27.2 Fresh Air Intake, Removing and Installing, RHD...............................................................................................................................................................................................................................................................................................................................................................................................................................................................4130
3.28 Driver Side Footwell Vent..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4131
3.28.1 Driver Side Footwell Vent, Removing and Installing...........................................................................................................................................................................................................................................................................................................................................................................................................................................................4131
3.28.2 Driver Side Footwell Vent, Removing and Installing, RHD......................................................................................................................................................................................................................................................................................................................................................................................................................................................4132
3.29 Front Passenger Side Footwell Vent.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4133
3.29.1 Front Passenger Side Footwell Vent, Removing and Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................4133
3.29.2 Front Passenger Side Footwell Vent, Removing and Installing, RHD.............................................................................................................................................................................................................................................................................................................................................................................................................................................4133
3.30 Vehicle Interior Forced Air Extraction.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4133
3.31 Glove Compartment Cooling..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4134
3.32 Heater Core Coolant Pipes..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4134
3.33 Control Module for Heat and A/C Components.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4136
3.34 Coolant Pump in Front of Electric Drive Power and Control Electronics -V508-.......................................................................................................................................................................................................................................................................................................................................................................................................................................4136
3.35 Coolant Pump in Front of High-Voltage Heater (PTC) -V509-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................4137
3.36 Temperature Sensor in Front of High-Voltage Heater (PTC) -G785-....................................................................................................................................................................................................................................................................................................................................................................................................................................................4138
3.37 Temperature Sensor after High-Voltage Battery Heat Exchanger -G786-................................................................................................................................................................................................................................................................................................................................................................................................................................................4139
3.38 Temperature Sensor after Heat Exchanger -G787-.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4140
3.39 Temperature Sensor after Electro-Drive Drive Motor -G788-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................4141
3.40 Temperature Sensor after Electric Drive Power and Control Electronics -G789-.......................................................................................................................................................................................................................................................................................................................................................................................................................................4142
3.41 High-Voltage Heater (PTC) -Z115-...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4143
3.42 Heater Coolant Shut-Off Valve -N279-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4144
3.43 High-Voltage Battery Coolant Shut-Off Valve -N540-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................4145
3.44 Display Control Head...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4147
3.44.1 Display Control Head, Removing and Installing, Electric Manual Climate Control System........................................................................................................................................................................................................................................................................................................................................................................................................................4147
3.44.2 Display Control Head, Removing and Installing, Climatronic...................................................................................................................................................................................................................................................................................................................................................................................................................................................4147
3.45 Temperature Control Door Motor -V68-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4148
3.45.1 Temperature Control Door Motor -V68-, Removing and Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................4148
3.45.2 Temperature Control Door Motor -V68-, Removing and Installing, RHD...........................................................................................................................................................................................................................................................................................................................................................................................................................................4150
3.46 Defroster Door Motor -V107-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4151
3.47 Recirculation Door Motor -V113-....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4152
3.47.1 Recirculation Door Motor -V113-, Removing and Installing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................4152
3.47.2 Recirculation Door Motor -V113-, Removing and Installing, RHD................................................................................................................................................................................................................................................................................................................................................................................................................................................4153
3.48 Left Temperature Control Door Motor -V158-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4154
3.48.1 Left Temperature Control Door Motor -V158-, Removing and Installing..........................................................................................................................................................................................................................................................................................................................................................................................................................................4154
3.48.2 Left Temperature Control Door Motor -V158-, Removing and Installing, RHD.....................................................................................................................................................................................................................................................................................................................................................................................................................................4156
3.49 Right Temperature Control Door Motor -V159-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4157
3.49.1 Right Temperature Control Door Motor -V159-, Removing and Installing.........................................................................................................................................................................................................................................................................................................................................................................................................................................4157
3.49.2 Right Temperature Control Door Motor -V159-, Removing and Installing, RHD....................................................................................................................................................................................................................................................................................................................................................................................................................................4158
3.50 Fresh Air/Recirculating Air/Back Pressure Door Motor -V425-........................................................................................................................................................................................................................................................................................................................................................................................................................................................4160
3.50.1 Fresh Air/Recirculating Air/Back Pressure Door Motor -V425-, Removing and Installing.........................................................................................................................................................................................................................................................................................................................................................................................................................4160
3.50.2 Fresh Air/Recirculating Air/Back Pressure Door Motor -V425-, Removing and Installing, RHD....................................................................................................................................................................................................................................................................................................................................................................................................................4161
3.51 Front Air Distribution Door Motor -V426- with Air Distribution Door Motor Position Sensor -G642-...................................................................................................................................................................................................................................................................................................................................................................................................................4162
3.52 Air Distribution Door Motor -V428-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4162
3.53 Fresh Air/Recirculating Air/Back Pressure Door Adjuster............................................................................................................................................................................................................................................................................................................................................................................................................................................................4162
3.54 Sunlight Photo Sensor -G107-/Sunlight Photo Sensor 2 -G134-........................................................................................................................................................................................................................................................................................................................................................................................................................................................4163
3.55 Air Quality Sensor -G238-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4164
3.55.1 Air Quality Sensor -G238-, Removing and Installing...........................................................................................................................................................................................................................................................................................................................................................................................................................................................4164
3.55.2 Air Quality Sensor -G238-, Removing and Installing, RHD......................................................................................................................................................................................................................................................................................................................................................................................................................................................4165
3.56 Outside Air Temperature Sensor -G17-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4165
3.56.1 Outside Air Temperature Sensor -G17-, Removing and Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................4165
3.56.2 Outside Air Temperature Sensor -G17-, Removing and Installing, GTI...........................................................................................................................................................................................................................................................................................................................................................................................................................................4166
3.57 Left Vent Temperature Sensor -G150-................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4166
3.58 Right Vent Temperature Sensor -G151-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4167
3.59 Center Vent Temperature Sensor -G191-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4167
3.60 Footwell Vent Temperature Sensor -G192-............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4167
3.61 Left Footwell Vent Temperature Sensor -G261-.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................4168
3.62 Right Footwell Vent Temperature Sensor -G262-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................4168
4 Disassembly and Assembly..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4169
4.1 Evaporator Housing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4169
5 Special Tools.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4170
6 Revision History..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4173
08-Body.pdf (p.4174-5605)...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4174
08-01 Body Repairs..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4174
00 – General, Technical Data................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4178
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4178
1.1 Safety Precautions..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4178
1.2 Vehicle Data....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4178
1.2.1 VIN.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4178
1.2.2 Type Plate................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4180
1.2.3 Vehicle Data Label........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4181
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4182
2.1 Alignment Bracket Set...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4182
2.2 Portal Gauge....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4183
2.2.1 2-Door Vehicle............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4183
2.2.2 4-Door Vehicle............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4184
2.3 Molded Foam Inserts.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4185
2.4 Galvanized Body Parts and High-Strength/Highest Strength Hot Formed Body Panels.................................................................................................................................................................................................................................................................................................................................................................................................................................4185
2.4.1 Structure.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4185
2.4.2 2-Door Vehicle............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4187
2.4.3 4-Door Vehicle............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4190
2.5 Laser Welds.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4192
3 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4193
3.1 Body Gap Dimensions.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4193
3.1.1 Body, Front...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4193
3.1.2 Body, Center..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4195
3.1.3 Body, Rear................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4196
3.2 Body Panel Dimensions...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4197
3.2.1 Body, Front...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4197
3.2.2 Body, Center..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4202
3.2.3 Body, Rear................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4210
3.2.4 Front Floor Assembly......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4213
3.2.5 Center Floor Assembly.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4215
3.2.6 Rear Floor Assembly.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4216
4 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4218
50 – Body Front.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4219
1 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4219
1.1 Right Console...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4219
1.2 Left Console....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4222
1.3 Subframe Mounting Bracket.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4227
1.4 Front Bumper Bracket............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4230
1.5 Upper Wheel Housing Longitudinal Member.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4232
1.6 Front Wheel Housing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4240
1.7 Subframe Mount Thread, Servicing................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4251
1.8 Front Longitudinal..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4256
1.9 Front Longitudinal Member, Partial Section, Removing and Installing.............................................................................................................................................................................................................................................................................................................................................................................................................................................4263
2 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4268
51 – Body Center, Chassis, Roof.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4269
1 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4269
1.1 Roof, Vehicles without Sunroof..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4269
1.2 Roof, Vehicle with Sunroof......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4284
1.3 Roof Pillar.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4300
1.4 Front Roof Crossmember..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4318
1.5 Roof Reinforcement, Vehicles without Sunroof....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4322
1.6 Rear Roof Cross Member..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4326
1.7 A-Pillar........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4331
1.8 A-Pillar Reinforcement..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4341
1.9 B-Pillar, 4-Door Vehicle........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4349
1.10 B-Pillar Reinforcement, 4-Door Vehicle.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4360
1.11 B-Pillar Reinforcement, 2-Door Vehicle.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4375
1.12 Outer Sill Panel, 4-Door Vehicle...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4388
1.13 Outer Sill Panel, 2-Door Vehicle...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4397
1.14 Outer Seat Cross Member Mount..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4404
1.15 Inner Seat Cross Member Mount..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4409
1.16 Sill Panel Front Reinforcement, Vehicles with 4-Doors..........................................................................................................................................................................................................................................................................................................................................................................................................................................................4414
1.17 Sill Panel Front Reinforcement, Vehicles with 2-Doors..........................................................................................................................................................................................................................................................................................................................................................................................................................................................4419
1.18 Sill Panel Rear Reinforcement, Vehicles with 4-Doors...........................................................................................................................................................................................................................................................................................................................................................................................................................................................4425
1.19 Sill Panel Rear Reinforcement, Vehicles with 2-Doors...........................................................................................................................................................................................................................................................................................................................................................................................................................................................4430
1.20 Center Seat Cross Member.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4435
2 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4441
53 – Body Rear..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4443
1 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4443
1.1 Rear Cross Panel................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4443
1.2 Tail Lamp Mount.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4447
1.3 End Crossmember.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4452
1.4 Luggage Compartment Floor.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4457
1.5 Rear Longitudinal Member, Partial Section.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................4463
1.6 Side Panel, Vehicles with 4-Doors...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4469
1.7 Side Panel, Vehicles with 2-Doors...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4480
1.8 Outer Wheel Housing Liner.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4491
2 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4496
3 Revision History......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4497
08-02 Body Repair-Body Collision Repair.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4501
1 Safety Instructions.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4505
1.1 Removing Components.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4505
1.2 Battery, Welding Work...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4505
1.3 Electronic Control Units............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4505
1.3.1 Procedure for Electronic Control Units after Accident Repairs.................................................................................................................................................................................................................................................................................................................................................................................................................................................4505
1.4 Paint, Glass, Upholstery, Trim......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4506
1.5 Fuel Tank or Fuel Lines.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4506
1.6 Air Conditioner.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4506
1.6.1 Remedy........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4506
1.7 Airbag System.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4507
1.8 Seat Belts, Checking................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4507
1.8.1 Belt Strap, Checking..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4507
1.8.2 Inertia Reel Locking Effect, Checking.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4508
1.8.3 Belt Lock, Visual Check.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4509
1.8.4 Belt Lock, Functional Check...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4509
1.8.5 Belt Guides and Lock Tongues, Checking........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4509
1.8.6 Securing Parts and Anchorage Points, Checking.................................................................................................................................................................................................................................................................................................................................................................................................................................................................4510
1.9 Safety Regulations for Belt Tensioners..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4510
1.10 Repairs on Vehicles with Belt Tensioners...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4510
1.10.1 Belt Tensioner Applications..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4511
1.11 Cutting, Straightening and/or Bending Operations on Vehicles with Airbag...........................................................................................................................................................................................................................................................................................................................................................................................................................................4512
1.12 Front Seats with Side Airbag.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4512
2 Basic Instructions........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4513
2.1 Diagnosis on Accident Vehicles......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4513
2.2 Conditions in Which Body and/or Parts are Passed for Painting.......................................................................................................................................................................................................................................................................................................................................................................................................................................................4513
2.3 Straightening.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4513
2.4 Parting Cuts........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4513
2.5 Replacement Body Sub-Parts and Part Sections........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4514
2.6 Original Joint......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4514
2.7 Galvanized Body Parts...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4514
2.8 Removing Material Remains...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4514
2.9 New Parts...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4514
2.10 Service Parts......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4515
3 Symbols...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4516
3.1 Symbols for Welding Operations......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4516
3.2 Symbols for Working Procedures......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4516
4 Body Repair Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4518
5 Materials for Body Repairs and General Body Repairs.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................4523
5.1 Adhesives...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4523
5.2 Sealants............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4526
5.3 Locking Fluids......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4527
5.4 Surface Protection Materials........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4527
5.5 Anti-Corrosion Materials............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4528
5.6 Chemical Materials..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4528
5.7 Filling Materials...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4529
6 Bodywork - Bonded Joints..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4530
6.1 EuroVan from MY 1991................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4530
6.1.2 Bonding Procedure.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4530
6.2 Types of Bonded Joints..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4530
6.2.1 Strength Bonded Joints........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4530
6.2.2 Spot Welded Bonded Joints.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4531
6.3 Repair Remedies for Partial Repairs.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4531
6.3.1 RP Spot Welding and Bonding...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4531
6.3.2 SG Welding and Bonding (Spot Welding Not Possible)............................................................................................................................................................................................................................................................................................................................................................................................................................................................4531
6.3.3 Extraction of Weld Fumes......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4531
6.3.4 Preparation...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4531
6.3.5 Supplementary Work............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4531
6.3.6 Instructions for DA 001 730 A1................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4532
7 Anti-Corrosion Measures...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4533
7.1 Anti-Corrosion Protection...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4533
7.2 Long-Term Body Protection...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4533
7.3 Electrolytic Galvanizing............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4534
7.4 Hot Galvanizing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4534
8 Disposal Information......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4535
8.1 Environmental Protection Practiced During Production................................................................................................................................................................................................................................................................................................................................................................................................................................................................4535
8.1.1 Recycling.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4535
8.1.2 Basic Environmental Protection Rules..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4535
8.2 Recycling...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4535
8.3 Plastics............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4536
8.3.1 Table 1- Frequently Used Base Polymers (Thermo- and Duroplastics)*............................................................................................................................................................................................................................................................................................................................................................................................................................................4536
8.3.2 Continuation of Table 1*......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4536
8.3.3 Table 2- Frequently Used Fillers and Reinforcing Materials*...................................................................................................................................................................................................................................................................................................................................................................................................................................................4537
8.3.4 Table 3- Frequently Used Elastomer-Base Polymers*.............................................................................................................................................................................................................................................................................................................................................................................................................................................................4537
8.4 Disposal............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4537
8.5 Releasing Gas from Strut............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4538
8.6 Airbag..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4538
8.6.1 Disposal......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4539
9 Repair Procedures.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4540
9.1 Accident Repairs....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4540
10 Contact Corrosion Protection.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4542
10.1 Connections/Joints of Aluminum/Magnesium and Steel.................................................................................................................................................................................................................................................................................................................................................................................................................................................................4542
11 Sheet Metal Repairs......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4543
11.1 Strengthened Steel Body Panels.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4543
11.2 Galvanized Body Parts..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4544
11.2.1 Preparation..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4544
11.2.2 Parting Cuts.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4544
11.2.3 Joint Techniques.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4544
11.3 Welding Galvanized Body Panels.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4544
11.3.1 SG Inert Gas Welding of Galvanized Panels....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4544
11.3.2 RP Welding of Galvanized Panels..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4545
11.3.3 Welding Transformer..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4545
11.3.4 Welding Tongs................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4545
11.4 Unbuttoning Test...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4545
12 Aluminum Repairs.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4546
12.1 Paint..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4546
12.2 Surface Preparation................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4546
12.3 Removing Dents.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4547
12.4 Temperature Regulation for Heat Treatment..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4547
13 Procedures for Repair of Synthetic Materials.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4548
13.1 Materials..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4548
13.2 Servicing Dents....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4550
13.3 Servicing Scratches................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4552
13.4 Servicing Cracks (up to 100 mm)....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4554
13.5 Servicing Holes (up to 30 mm diameter).............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4557
13.6 Synthetic Material Repairs (Fiberglass Materials)..................................................................................................................................................................................................................................................................................................................................................................................................................................................................4560
14 Repairing Procedure......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4561
14.1 Repair Procedure...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4561
14.1.1 Servicing Rupture/Hole.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4562
14.1.2 Applying Fiberglass Mats.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4562
14.1.3 Servicing Damaged Surfaces...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4563
15 Repairing Glass..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4564
15.1 Repairing Windshields..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4564
15.1.1 Prerequisites................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4564
15.1.2 Special Tools and Workshop Equipment Required................................................................................................................................................................................................................................................................................................................................................................................................................................................................4565
15.1.3 Description of Repairs.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4566
08-03 General Paint Information.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4572
00 – General, Technical Data................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4578
1 Safety Precautions....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4578
1.1 Safety Precautions when Painting Vehicles with Natural Gas......................................................................................................................................................................................................................................................................................................................................................................................................................................................4578
1.2 Safety Precautions when Painting Vehicles with Electric Drive...................................................................................................................................................................................................................................................................................................................................................................................................................................................4579
2 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4580
2.1 Factory Paint Paint Structure...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4580
2.2 Customer Service Paint Paint Structure..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4581
2.3 Reduced Paint Structure in Engine Compartment and Inner Hood....................................................................................................................................................................................................................................................................................................................................................................................................................................................4584
2.4 Repair Instructions for the Underbody and Stone Chip Protection.................................................................................................................................................................................................................................................................................................................................................................................................................................................4584
2.5 Pretreatment of the Adhesive Surface with Two-Part Epoxy Primer Filler when Replacing Laser-Welded Roofs........................................................................................................................................................................................................................................................................................................................................................................................................4586
2.6 Fender Corrosion Repair Measures, in Wheel Housing Liner Contact Area...........................................................................................................................................................................................................................................................................................................................................................................................................................................4587
2.7 Fold Corrosion Servicing Notes..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4588
2.8 Corrosion Protection for Body, Attached and Welded Parts........................................................................................................................................................................................................................................................................................................................................................................................................................................................4590
3 Original Products.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4592
3.1 General Application Instructions for Repair and Painting Systems................................................................................................................................................................................................................................................................................................................................................................................................................................................4592
3.1.1 Aqua Premium Application Instructions for Water-Soluble Products..........................................................................................................................................................................................................................................................................................................................................................................................................................................4592
3.1.2 Gloss Level Adjustment of HS Clear Lacquer and HS Top Coat................................................................................................................................................................................................................................................................................................................................................................................................................................................4595
3.1.3 Repair Paint System for Matte Painted Vehicles............................................................................................................................................................................................................................................................................................................................................................................................................................................................4603
3.1.4 Paint System for Plastic Parts............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4608
3.1.5 Aqua Premium System, Touch-Up System for Two Layer Colors.................................................................................................................................................................................................................................................................................................................................................................................................................................................4614
3.1.6 Aqua Premium System, Touch-Up System for Three Layer Colors...............................................................................................................................................................................................................................................................................................................................................................................................................................................4619
3.1.7 Aquaplus Design and Multi-Color Paintwork.................................................................................................................................................................................................................................................................................................................................................................................................................................................................4624
3.2 Filling Paste...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4628
3.2.1 Two-Part Steel Filling Paste Set..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4628
3.2.2 Two-Part Fine Filling Paste...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4631
3.2.3 Two-Part Fine Filling Paste, Flexible.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4634
3.2.4 Two-Part Spray Filling Paste..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4637
3.2.5 Two-Part IR Premium Filling Paste.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4641
3.2.6 Two-Part Diamond Aluminum Filling Paste...................................................................................................................................................................................................................................................................................................................................................................................................................................................................4645
3.3 Primer Metal....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4647
3.3.1 One-Part Anti-Corrosion Wash Primer.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................4647
3.3.2 One-Part Wash Primer......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4651
3.3.3 Two-Part Wash Primer......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4655
3.4 Plastic Primer..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4658
3.4.1 Adhesion Promoter (Glazing)...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4658
3.5 Filler..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4662
3.5.1 Two-Part HS Vario Filler..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4662
3.5.2 Two-Part HS Premium Filler................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4670
3.5.3 Two-Part HS Mixed Filler..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4677
3.5.4 Two-Part HS Performance Filler............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4689
3.5.5 Two-Part Synthetic Adhesion Filler........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4695
3.5.6 Two-Part HS Wet-in-Wet Filler.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4700
3.6 Top Coats.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4704
3.6.1 Two-Part HS Top Coat......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4704
3.6.2 Aquaplus System (Solid and Metallic)......................................................................................................................................................................................................................................................................................................................................................................................................................................................................4710
3.6.3 Aquaplus System (Pearl Effect and Heliochrome)............................................................................................................................................................................................................................................................................................................................................................................................................................................................4717
3.6.4 Aquaplus Touch-Up System..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4723
3.6.5 Aqua Premium System.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4727
3.6.6 Aqua Premium Touch-Up System..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4737
3.6.7 Aqua Premium System (Rim Paintwork).......................................................................................................................................................................................................................................................................................................................................................................................................................................................................4742
3.7 Clear Coats.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4749
3.7.1 Two-Part HS Clear Coat....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4749
3.7.2 Two-Part MS Matt Clear Coat...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4755
3.7.3 Two-Part HS Vario Clear Coat..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4758
3.7.4 Two-Part HS Optimum Clear Coat............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4764
3.7.5 Two-Part HS Optimum Plus Clear Coat.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................4767
3.7.6 Two-Part Brilliant Clear Coat.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4771
3.7.7 Two-Part HS Brilliant Plus Clear Coat.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4775
3.7.8 Two-Part HS Performance Clear Coat........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4780
3.7.9 Blender...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4784
3.8 Hardener........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4788
3.8.1 Two-Part HS Hardener......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4788
3.8.2 Two-Part VHS Hardener and Two-Part VHS Performance Hardener...............................................................................................................................................................................................................................................................................................................................................................................................................................................4792
3.8.3 Two-Part Adhesive Filler Hardener.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4796
3.8.4 Aqua Premium Hardener.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4796
3.9 Thinners........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4796
3.9.1 Two-Part Thinner..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4796
3.9.2 HS Spot Thinner...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4800
3.9.3 Purified Water............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4802
3.10 Preservation...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4802
3.10.1 Preserving Wax...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4802
3.10.2 Cavity Sealant...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4803
3.10.3 Preserving Wax (Spray Can)...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4806
3.11 Underbody Protection...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4807
3.11.1 Long-Term Underbody Protection -D 314 D36 M2-, Gray......................................................................................................................................................................................................................................................................................................................................................................................................................................................4807
3.11.2 Long-Term Underbody Protection -D 314 D37 M2-, Black.....................................................................................................................................................................................................................................................................................................................................................................................................................................................4810
3.11.3 Long-Term Underbody Protection -D 314 D38 M2-, Bright Color..............................................................................................................................................................................................................................................................................................................................................................................................................................................4813
3.12 Stone Chip Protection..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4816
3.12.1 Stone Chip Protection -AKR 311 KD1 05-...................................................................................................................................................................................................................................................................................................................................................................................................................................................................4816
3.12.2 Stone Chip Protection -AKR 311 KD1 10-...................................................................................................................................................................................................................................................................................................................................................................................................................................................................4818
3.13 Wax Underbody Protection.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4823
3.13.1 Wax Underbody Protection -D 316 D38 A2-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................4823
3.13.2 Wax Underbody Protection -D 316 000 A1-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................4825
3.13.3 Wax Spray -D 322 100 M2-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4826
3.14 Sealing Materials..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4828
3.14.1 Polyurethane Adhesive Sealant............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4828
3.14.2 Sprayable Sealant........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4830
3.14.3 Adhesive/Sealant.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4833
3.15 Cleaning Agent.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4836
3.15.1 Silicone Remover.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4836
3.15.2 Plastic Cleaner..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4837
3.15.3 Antistatic Plastic Cleaner...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4838
3.15.4 Industrial Dirt Remover..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4839
3.16 SprayMax System................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4840
3.16.1 One-Part Anti-Corrosion Primer...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4840
3.16.2 One-Part Test Paint......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4843
3.16.3 One-Part Clear Coat......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4845
3.16.4 One-Part Wash Primer.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4848
3.16.5 One-Part Clean Spray Can -LLS MAX 099-, -LLS MAX 100-, Aquaplus System...................................................................................................................................................................................................................................................................................................................................................................................................................................4851
3.16.6 One-Part Clean Spray Can -LLS MAX 112-, Aqua Premium System..............................................................................................................................................................................................................................................................................................................................................................................................................................................4857
3.16.7 Two-Part Filler..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4864
3.16.8 Two-Part Clear Coat......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4870
3.16.9 Two-Part Epoxy Primer Filler.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4874
3.16.10 Two-Part Wash Primer....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4879
3.16.11 Silicone Remover -LLS MAX 007-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4883
3.16.12 Silicone Remover, Long -LLS MAX 008-....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4886
3.16.13 Blender.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4887
3.16.14 Bonding Agent...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4889
3.17 Additional Materials...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4892
3.17.1 Matting Component - ALN 775 106-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4892
3.17.2 Matting Component -LVM 769 810 A2-.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................4898
3.17.3 Structuring Component....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4901
3.17.4 Aquaplus Touch-Up Additive...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4906
3.17.5 Aqua Premium System Additive.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4906
4 Workshop Equipment....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4908
4.1 Tools...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4908
4.1.1 Spray Can Filling Device -VAS6425-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4908
4.1.2 Paint Thickness Tester -VAS6272-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4909
4.1.3 Paint Thickness Tester -VAS6197-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4909
4.1.4 Paint Thickness Test -VAS5278-............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4909
4.1.5 Stone Chip Tester -VAS5102A-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4911
4.1.6 Pneumatic Brush Grinder Set -VAS6446-.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4912
4.1.7 Brush Grinder Set -VAS6776-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4913
4.1.8 Suction Feed Spray Gun -VAG1538-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4914
4.1.9 Infrared Dryer -VAS6873-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4915
4.1.10 Stand -VAS6873/1-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4915
4.1.11 Infrared Dryer -VAS6874-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4916
4.1.12 Infrared Dryer -VAS6875-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4916
4.1.13 Infrared Dryer -VAS6876-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4917
4.1.14 Infrared Dryer -VAS6877-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4918
4.1.15 Infrared Dryer -VAS6878-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4919
4.1.16 Infrared Dryer -VAS6879-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4920
4.2 Dust Cloths.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4920
4.2.1 Dust Cloth -VAS6177-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4920
4.2.2 White Polishing Cloth -VAS6176-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4921
4.2.3 Primary Duster -VAS5542-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4921
4.2.4 Professional Cleaning Cloth -VAS6006-.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4922
5 Revision History......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4923
08-04 Body Exterior.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4927
50 – Body Front.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4935
1 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4935
1.1 Bulkhead Materials..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4935
1.2 Bulkhead Overview...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4936
1.3 Fender Insulation Component Locations...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4937
1.4 Front Fender Overview...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4937
1.5 Lock Carrier Overview...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4939
1.6 Lock Carrier Service Position, Setting..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4940
1.7 Noise Insulation Overview.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4942
1.8 Plenum Chamber Bulkhead Overview................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4943
1.9 Plenum Chamber Cover Overview...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4944
1.10 Tunnel Bridge Overview.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4945
1.11 Underbody Impact Guard Overview................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4946
1.12 Underbody Trim Panel, Center Overview..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4947
1.13 Underbody Trim Panel, Rear Overview............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4948
2 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4949
3 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4950
3.1 Charge Air Cooler Pressure Hose and Coupling, Disconnecting and Connecting......................................................................................................................................................................................................................................................................................................................................................................................................................................4950
3.2 Front Fender....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4950
3.3 Fender Brace....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4953
3.4 Lock Carrier with Attachments...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4953
3.5 Plenum Chamber Cover............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4955
4 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4958
55 – Hood, Lids.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4960
1 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4961
1.1 Hood Overview...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4961
1.2 Hood Seal Overview..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4962
1.3 Hood Locking Component Overview.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4963
1.4 Hood Release, Disconnecting.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4964
1.5 Hood, Adjusting.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4965
1.6 Hood Latch, Adjusting...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4966
1.7 Hood Striker Pin, Adjusting.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4967
1.8 Rear Lid Adjusting..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4968
1.9 Rear Lid Adjustment Buffer, Adjusting...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................4969
1.10 Rear Lid Gas-Filled Strut Overview.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................4971
1.11 Rear Lid Gas Strut, Venting....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4972
1.12 Rear Lid Hinge Overview........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4972
1.13 Rear Lid Overview..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4973
1.14 Rear Lid Striker Pin, Adjusting................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4973
1.15 Fuel Filler Door Unit and Actuator Overview....................................................................................................................................................................................................................................................................................................................................................................................................................................................................4974
2 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4975
3 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4976
3.1 Hood............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4976
3.2 Hood Gas Strut..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4979
3.3 Hood Gas-Filled Strut Mount.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4981
3.4 Hood Hinge......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4981
3.5 Hood Insulation.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4983
3.6 Hood Latch......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4985
3.7 Hood Release Lever..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4988
3.8 Hood Striker Pin................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4990
3.9 Rear Lid........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4990
3.10 Rear Lid Adjusting Buffer......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4994
3.11 Rear Lid Gas Strut.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4994
3.12 Rear Lid Hinge.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4996
3.13 Rear Lid Lock..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4998
3.14 Rear Lid Release Element.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4999
3.15 Rear Lid Seal..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5001
3.16 Rear Lid Striker Pin...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5004
3.17 Rear Lid Unlocking Element with Rearview Camera................................................................................................................................................................................................................................................................................................................................................................................................................................................................5004
3.18 Fuel Filler Door Unit..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5006
3.19 Fuel Filler Door Actuator......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5009
4 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5011
57 – Front Doors, Central Locking System....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5012
1 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5012
1.1 Central Locking Component Overview..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5012
1.2 Door, Adjusting.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5014
1.3 Door Handle and Door Lock Overview..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5018
1.4 Door Hinge Overview.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5019
1.5 Folding Remote Vehicle Key Battery Overview.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5021
1.6 Front Door Overview.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5022
1.7 Insulation Overview, 2-Door Vehicle.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5024
1.8 Insulation Overview, 4-Door Vehicle.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5025
1.9 New Door Hinges, Lubricating....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5026
1.10 Remote Vehicle Keys, Adaptation................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5026
2 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5028
3 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5029
3.1 Cap without Lock Cylinder.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5029
3.2 Cover, 2-Door Vehicle...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5031
3.3 Door............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5033
3.4 Door Handle.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5035
3.5 Door Lock.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5037
3.6 Inner Door Seal.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5039
3.7 Inner Window Shaft Strip........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5041
3.8 Lock Cylinder Cover Cap.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5042
3.9 Lock Cylinder...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5043
3.10 Mounting Bracket...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5046
3.11 Outer Window Recess Seal.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5046
3.12 Outer Door Seal, 2-Door Vehicle................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5047
3.13 Outer Door Seal, 4-Door Vehicle................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5048
3.14 Remote Foldable Vehicle Key Battery............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5049
3.15 Subframe.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5050
3.16 Trim...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5055
4 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5058
58 – Rear Doors.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5060
1 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5060
1.1 Door Adjusting..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5060
1.2 Door Handle and Door Lock Overview..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5064
1.3 Door Hinge Overview.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5065
1.4 Insulation Overview.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5067
1.5 New Door Hinge, Lubricating.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5068
1.6 Rear Door Overview..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5069
2 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5071
3 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5072
3.1 Cover...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5072
3.2 Door............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5074
3.3 Door Handle.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5076
3.4 Door Lock.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5078
3.5 Inner Door Seal.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5079
3.6 Inner Window Shaft Strip........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5082
3.7 Mounting Bracket................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5082
3.8 Outer Door Seal.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5084
3.9 Outer Window Recess Seal........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5085
3.10 Subframe.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5086
3.11 Trim...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5092
4 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5095
60 – Sunroof................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5097
1 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5097
1.1 Installation Unit Overview......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5097
1.2 Operating without Electricity...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5098
1.3 Panel Seal, Adjusting...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5098
1.4 Parallel Movement, Checking.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5099
1.5 Parallel Movement, Adjusting....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5099
1.6 Sunroof Glass Panel Drive Zero Position, Adjusting..............................................................................................................................................................................................................................................................................................................................................................................................................................................................5099
1.7 Sunroof with Glass Panel Function...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5100
1.8 Sunroof with Glass Panel Overview...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5101
1.9 Sunroof Glass Panel Height, Adjusting...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5102
1.10 Water Drain Hoses, Cleaning....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5103
1.11 Wind Deflector, Adjusting......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5105
2 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5107
3 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5108
3.1 Bellows.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5108
3.2 Installation Unit...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5110
3.3 Panel Seal, Replacing...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5112
3.4 Rear Guide and Guide Catch......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5112
3.5 Slotted Guide Rail..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5113
3.6 Sunroof Glass Panel.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5114
3.7 Sun Shade.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5115
3.8 Sunroof Glass Panel Drive.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5115
3.9 Sunroof Glass Panel Rotary Switch...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5116
3.10 Wind Deflector.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5116
4 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5118
63 – Bumpers................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5119
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5119
1.1 Front Bumper Cover..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5119
1.2 Rear Bumper Cover...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5119
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5120
2.1 Front Bumper Overviews..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5120
2.1.1 Front Bumper Cover Overview...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5120
2.1.2 Front Bumper Cover Attachments............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5122
2.2 Front Bumper Overviews, GTI.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5123
2.2.1 Bumper Cover Overview.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5123
2.2.2 Bumper Cover Attachments..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5124
2.3 Front Bumper Overviews, Golf R..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5126
2.3.1 Bumper Cover Overview, Golf R.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5126
2.3.2 Bumper Cover Attachments..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5127
2.4 Front Bumper Carrier Overview...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5128
2.5 Side Guide Overview.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5129
2.6 Rear Bumper Cover...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5130
2.6.1 Rear Bumper Cover Overview................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5130
2.6.2 Rear Bumper Cover Attachments.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5131
2.7 Rear Bumper Overviews, GTI......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5132
2.7.1 Bumper Cover Overview.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5132
2.7.2 Bumper Cover Attachments..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5133
2.8 Rear Bumper Overviews, Golf R...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5134
2.8.1 Bumper Cover Overview.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5134
2.8.2 Bumper Cover Attachments..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5135
2.9 Rear Bumper Cover Substructure Overview.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5136
2.10 Rear Bumper Carrier Overview...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5137
2.11 Trailer Hitch Overview.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5138
2.12 Parking Aid Mount, Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5138
2.12.1 Tools....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5138
2.12.2 Materials................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5139
2.12.3 Mount, Installing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5139
2.12.4 Minimum Curing Time......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5143
3 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5144
4 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5145
4.1 Front Bumper Cover..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5145
4.2 Front Bumper, GTI...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5147
4.2.1 Front Bumper Cover........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5147
4.2.2 Inner Assembly Components.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5150
4.2.3 Front Spoiler.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5151
4.2.4 License Plate Holder......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5153
4.3 Front Bumper, Golf R............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5154
4.3.1 Front Bumper Cover........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5154
4.3.2 Support...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5156
4.4 License Plate Holder............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5157
4.5 Rear Bumper Cover...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5158
4.6 Rear Bumper Cover, GTI..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5160
4.7 Rear Bumper Cover, Golf R.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5162
4.8 Rear Bumper License Plate Holder................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5165
4.9 Parking Aid Mount, Installing...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5166
4.9.1 Tools.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5166
4.9.2 Materials.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5166
4.9.3 Mount, Installing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5167
4.9.4 Minimum Curing Time.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5170
5 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5171
64 – Glass, Window Regulators...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5172
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5172
1.1 Materials.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5172
1.2 Installation Information........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5172
1.3 Minimum Curing Time.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5173
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5174
2.1 Rear Window Overview............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5174
2.2 Side Window Overview............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5175
2.3 Windshield Overview.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5176
2.4 Undamaged Window, Preparing for Glazing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5177
2.5 Preparing New Window without Pre-Coating for Glazing............................................................................................................................................................................................................................................................................................................................................................................................................................................................5178
2.6 Window Flange, Preparing for Glazing............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5179
3 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5182
4 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5183
4.1 Flush Bonded Windows............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5183
4.1.1 Adhesive Sealant, Removing from Window....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5183
4.1.2 Broken Side Window, Removing..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5183
4.1.3 Damaged Rear Window, Removing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5183
4.1.4 Rear Window, Installing...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5184
4.1.5 Side Window, Installing...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5184
4.1.6 Undamaged Rear Window, Removing...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5185
4.1.7 Undamaged Side Window, Removing...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5186
4.1.8 Windshield................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5187
4.2 Front Door Window...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5189
4.3 Front Door Window Regulator Motor...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5193
4.4 Front Door Window Guide.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5196
4.5 Rear Door Window................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5197
4.6 Rear Door Window Regulator Motor................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5200
4.7 Rear Door Window Crank..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5203
4.8 Rear Door Window Guide..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5203
4.9 Rear Door Fixed Door Window.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5205
5 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5208
66 – Exterior Equipment.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5210
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5210
1.1 Roof Edge Spoiler...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5210
1.1.1 Roof Edge Spoiler Materials...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5210
1.1.2 Preparing Roof Edge Spoiler Bodywork for Adhesive.........................................................................................................................................................................................................................................................................................................................................................................................................................................................5210
1.1.3 Roof Edge Spoiler Installation Information................................................................................................................................................................................................................................................................................................................................................................................................................................................................5211
1.1.4 Roof Edge Spoiler Minimum Curing Time.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5211
1.1.5 Roof Edge Spoiler Adhesive Sealant, Removing from Window..................................................................................................................................................................................................................................................................................................................................................................................................................................................5211
1.2 Name Plates and Emblems Installation Information................................................................................................................................................................................................................................................................................................................................................................................................................................................................5212
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5213
2.1 Anti-Rodent System Overview.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5213
2.2 Drip Rail Overview..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5215
2.3 Exterior Mirror Overview........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5216
2.4 Front Wheel Housing Liner Overview..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5217
2.5 Rear Wheel Housing Liner Overview...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5218
2.6 Roof Edge Spoiler Overview......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5219
2.7 Sill Panel Cover Overview.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5220
2.8 Sill Panel Extension Overview, GTI..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5221
2.9 Sill Panel Extension Overview, Golf R...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5221
2.10 Special Component Overview, Golf R.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5223
2.11 Wheel Cover Trim Overview......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5224
3 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5225
3.1 Rear Name Plate Dimensions......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5225
3.2 Rear Name Plate, GTI............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5226
3.3 Rear Name Plate, Golf R.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5227
3.4 Emblem Adidas on B-Pillar.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5228
3.5 Emblem STYLE on B-Pillar........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5229
3.6 Tightening Specifications.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5229
4 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5231
4.1 Anti-Rodent System..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5231
4.2 Drip Rail.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5232
4.3 Emblem on Radiator Grille, Golf R...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5235
4.4 Exterior Rearview Mirror........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5236
4.4.1 Mirror Glass..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5236
4.4.2 Adjusting Unit with Motor.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5238
4.4.3 Frame.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5239
4.4.4 Mirror Housing............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5241
4.4.5 Turn Signal and Entry Lamp Inside Exterior Mirror.........................................................................................................................................................................................................................................................................................................................................................................................................................................................5243
4.4.6 Exterior Rearview Mirror..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5244
4.5 Front Wheel Housing Liner.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5245
4.6 Rear Wheel Housing Liner........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5247
4.7 Radiator Grille.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5250
4.8 Roof Edge Spoiler...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5252
4.9 Roof Edge Spoiler Retaining Strip...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5254
4.10 Sill Cover Strip Installation Instructions.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5256
4.11 Sill Cover Strip...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5257
4.12 Sill Panel Cover...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5258
4.13 Sill Panel Extension, GTI......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5259
4.14 Sill Panel Extension, Golf R...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5264
4.15 Stone Chip Protective Molding..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5268
4.16 Wheel Cover Trim...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5272
5 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5273
08-05 Body Interior.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5278
68 – Interior Equipment.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5282
1 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5282
1.1 Interior Rearview Mirror........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5282
1.1.1 Automatic Dimming Interior Rearview Mirror................................................................................................................................................................................................................................................................................................................................................................................................................................................................5282
2 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5283
2.1 Grab Handles....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5283
2.1.1 Roof Grab Handles.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5283
2.2 Interior Rearview Mirror........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5284
2.2.1 Interior Rearview Mirror with Rain Sensor Retaining Plate, Attaching......................................................................................................................................................................................................................................................................................................................................................................................................................................5284
2.2.2 Interior Rearview Mirror with Rain Sensor.................................................................................................................................................................................................................................................................................................................................................................................................................................................................5285
2.2.3 Interior Rearview Mirror..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5286
2.2.4 Interior Rearview Mirror Base Plate, without Rain Sensor, Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................5287
2.3 Sill Panel Trim.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5289
2.3.1 Sill Panel Trim, 2-door...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5289
2.3.2 Sill Panel Trim, 4-door...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5290
2.3.3 Trim, Wheel Housing, 4-door, Without Side Airbag, from 06.05..............................................................................................................................................................................................................................................................................................................................................................................................................................................5292
2.3.4 Wheel Housing Trim, 4-door................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5293
2.4 Storage Compartments, Covers and Trim...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5295
2.4.1 Center Console, Basis, Golf from MY 04....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5296
2.4.2 Center Console, Basis, Golf from MY 09....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5299
2.4.3 Center Console, Basis, Golf from MY 09....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5304
2.4.4 Center Console, Highline, Golf from MY 04.................................................................................................................................................................................................................................................................................................................................................................................................................................................................5308
2.4.5 Center Console, Highline, Golf from MY 09.................................................................................................................................................................................................................................................................................................................................................................................................................................................................5317
2.4.6 Center Console, Highline, Golf from MY 09.................................................................................................................................................................................................................................................................................................................................................................................................................................................................5327
2.4.7 Cover, Center, Golf from MY 00............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5330
2.4.8 Cover, Center, Golf from MY 04............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5331
2.4.9 Cupholder, Center Console, Highline.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................5332
2.4.10 Cupholder, Center Console, Highline, Servicing...........................................................................................................................................................................................................................................................................................................................................................................................................................................................5333
2.4.11 Decorative Trim, Instrument Panel, Golf from MY 04.......................................................................................................................................................................................................................................................................................................................................................................................................................................................5336
2.4.12 Decorative Trim, Instrument Panel, Golf from MY 09.......................................................................................................................................................................................................................................................................................................................................................................................................................................................5337
2.4.13 Driver Side Footwell Cover...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5338
2.4.14 Driver Side Left Trim....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5339
2.4.15 Driver Side Right Trim...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5341
2.4.16 Eyeglass Compartment in Headliner........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5344
2.4.17 Frame in Headliner.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5345
2.4.18 Glove Compartment........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5346
2.4.19 Glove Compartment Lock Cylinder..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5350
2.4.20 Instrument Panel Side Covers.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5351
2.4.21 Mounting Bracket, Center Console, Golf from MY 2004......................................................................................................................................................................................................................................................................................................................................................................................................................................................5352
2.4.22 Mounting Bracket, Center Console and Footwell Trim, Rabbit from MY 09....................................................................................................................................................................................................................................................................................................................................................................................................................................5356
2.4.23 Storage Compartment/Ashtray, Golf from MY 04.............................................................................................................................................................................................................................................................................................................................................................................................................................................................5361
2.4.24 Storage Compartment/Ashtray, Golf from MY 09.............................................................................................................................................................................................................................................................................................................................................................................................................................................................5362
2.4.25 Storage Compartment, Instrument Panel, Center, Golf from MY 09...........................................................................................................................................................................................................................................................................................................................................................................................................................................5362
2.4.26 Steering Column Trim.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5363
2.4.27 Sun Visor................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5364
2.4.28 Trim, Instrument Panel, Center, Golf from MY 09..........................................................................................................................................................................................................................................................................................................................................................................................................................................................5368
2.4.29 Trim, Instrument Panel, Center, Golf from MY 04..........................................................................................................................................................................................................................................................................................................................................................................................................................................................5368
2.4.30 Trim, A/C and Heater Controls, Golf from MY 09...........................................................................................................................................................................................................................................................................................................................................................................................................................................................5369
2.4.31 Vents, Instrument Panel, Center, Vehicles without Climatronic, Golf from MY 04...........................................................................................................................................................................................................................................................................................................................................................................................................................5370
2.4.32 Vents, Instrument Panel, Center, Vehicles with Climatronic, Golf from MY 04..............................................................................................................................................................................................................................................................................................................................................................................................................................5372
2.4.33 Vent, Instrument Panel, Center, Golf from MY 09..........................................................................................................................................................................................................................................................................................................................................................................................................................................................5375
3 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5377
69 – Passenger Protection, Airbags, Seat Belts..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5378
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5379
1.1 Airbag, Belt Tensioner and Battery Cut-Out Units, General Safety Precautions....................................................................................................................................................................................................................................................................................................................................................................................................................................5379
1.2 Airbag, Belt Tensioner and Battery Cut-Out Units, Storage, Transporting and Disposal............................................................................................................................................................................................................................................................................................................................................................................................................................5380
1.3 Belt Tensioner, Special Instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5380
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5382
2.1 Airbag..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5382
2.1.1 Airbag Component Location Overview........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5382
2.1.2 Airbag, Belt Tensioner and Battery Cut-Out Units, General Safety Precautions..............................................................................................................................................................................................................................................................................................................................................................................................................................5384
2.1.3 Airbag, Belt Tensioner and Battery Cut-Out Units, Storage, Transporting and Disposal......................................................................................................................................................................................................................................................................................................................................................................................................................5385
2.1.4 Airbag Units, Removing and Installing After an Accident...................................................................................................................................................................................................................................................................................................................................................................................................................................................5385
2.1.6 Driver and Passenger Airbag, Special Notes................................................................................................................................................................................................................................................................................................................................................................................................................................................................5386
2.1.7 Side Airbag Module, Special Notes.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5386
2.2 LATCH Child Seat Anchors, Inspecting after an Accident..........................................................................................................................................................................................................................................................................................................................................................................................................................................................5386
2.3 Passive Occupant Detection System...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5386
2.3.1 After an Accident with Belt Tensioner and/or Airbag Deployment............................................................................................................................................................................................................................................................................................................................................................................................................................................5386
2.3.2 Passive Occupant Detection System, Safety Precautions.....................................................................................................................................................................................................................................................................................................................................................................................................................................................5387
2.3.3 Passive Occupant Detection System Assembly Overview.......................................................................................................................................................................................................................................................................................................................................................................................................................................................5388
2.3.4 Passive Occupant Detection System Repair Kit Components...................................................................................................................................................................................................................................................................................................................................................................................................................................................5388
2.4 Seat Belts......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5390
2.4.1 Front Seat Belts, 2-door, Assembly Overview...............................................................................................................................................................................................................................................................................................................................................................................................................................................................5390
2.4.2 Front Seat Belts, 4-door, Assembly Overview...............................................................................................................................................................................................................................................................................................................................................................................................................................................................5391
2.4.3 Rear Outer Seat Belts Assembly Overview...................................................................................................................................................................................................................................................................................................................................................................................................................................................................5392
2.4.4 Rear Center Three-Point Seat Belt Assembly Overview.......................................................................................................................................................................................................................................................................................................................................................................................................................................................5393
2.5 Seat Belts, Inspecting..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5394
2.5.1 Belt Webbing, Checking....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5394
2.5.2 Belt Latch, Inspection....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5395
2.5.3 Belt Latch, Checking Function.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5395
2.5.4 Belt Guide Rings and Locking Tongue, Checking.............................................................................................................................................................................................................................................................................................................................................................................................................................................................5395
2.5.5 Mounting Components and Mounting Points, Checking.........................................................................................................................................................................................................................................................................................................................................................................................................................................................5396
2.5.6 Retractor, Checking Locking Function......................................................................................................................................................................................................................................................................................................................................................................................................................................................................5396
3 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5397
3.1 Airbag..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5397
3.1.1 Airbag Control Module J234................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5397
3.1.2 Air Bag, Driver Side, Golf from MY 04.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5399
3.1.3 Air Bag, Driver Side, Golf from MY 09.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5402
3.1.4 Airbag Spiral Spring/Return Spring With Slip Ring F138....................................................................................................................................................................................................................................................................................................................................................................................................................................................5406
3.1.5 Driver and Passenger Side Airbag..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5406
3.1.6 Driver and Passenger Side Curtain Airbags.................................................................................................................................................................................................................................................................................................................................................................................................................................................................5409
3.1.7 Driver and Front Passenger Side Curtain Airbag, Golf from MY 2009, 4-door.................................................................................................................................................................................................................................................................................................................................................................................................................................5411
3.1.8 Front Passenger Seat Occupant Sensor G128.................................................................................................................................................................................................................................................................................................................................................................................................................................................................5415
3.1.9 Knee Airbag, Golf from MY 09..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5418
3.1.10 Knee Airbag Bracket, Rabbit from MY 09...................................................................................................................................................................................................................................................................................................................................................................................................................................................................5420
3.1.11 Passenger Airbag Unit....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5423
3.1.12 Rear Side Airbag, 4-door.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5428
3.2 Crash Sensors...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5430
3.2.1 Driver Thorax Airbag Crash Sensor, Golf from MY 09........................................................................................................................................................................................................................................................................................................................................................................................................................................................5430
3.2.2 Driver Side Rear Side Airbag Crash Sensor G256, Golf from MY 09...........................................................................................................................................................................................................................................................................................................................................................................................................................................5432
3.2.3 Front Door Crash Sensors, Golf from MY 04.................................................................................................................................................................................................................................................................................................................................................................................................................................................................5432
3.2.4 Front Passenger Thorax Airbag Crash Sensor G180, Golf from MY 09..........................................................................................................................................................................................................................................................................................................................................................................................................................................5434
3.2.5 Front Passenger Side Rear Side Airbag Crash Sensor G257, Golf from MY 09..................................................................................................................................................................................................................................................................................................................................................................................................................................5434
3.2.6 Rear Wheel Housing Crash Sensors, 2-door, Golf 2004.......................................................................................................................................................................................................................................................................................................................................................................................................................................................5435
3.2.7 Rear Wheel Housing Crash Sensors, 4-door, Golf 2004.......................................................................................................................................................................................................................................................................................................................................................................................................................................................5436
3.3 Passive Occupant Detection System...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5439
3.3.1 Passive Occupant Detection System Components, Manual Seats, Removing......................................................................................................................................................................................................................................................................................................................................................................................................................................5439
3.3.2 Passive Occupant Detection System Repair Kit, Manual Seats, Installing....................................................................................................................................................................................................................................................................................................................................................................................................................................5442
3.3.3 Passive Occupant Detection System Components, Power Seats, Removing.......................................................................................................................................................................................................................................................................................................................................................................................................................................5442
3.3.4 Passive Occupant Detection System Repair Kit, Power Seats, Installing.....................................................................................................................................................................................................................................................................................................................................................................................................................................5446
3.4 Seat Belts......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5447
3.4.1 Belt Latch, 2-door........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5447
3.4.2 Belt Latch, 4-door........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5449
3.4.3 Center Rear Lap Belt......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5450
3.4.4 Front Seat Belts, 2-door..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5451
3.4.5 Front Seat Belts, 4-door..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5453
3.4.6 Front Seat Belt Height Adjuster...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5455
3.4.7 Rear Outer Seat Belts.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5456
3.4.8 Rear Center Three-Point Seat Belt.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5459
3.4.9 Rear Double Belt Latch....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5460
4 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5462
70 – Interior Trim..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5463
1 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5463
1.1 Instrument Panel................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5463
1.1.1 Instrument Panel, Golf from MY 04, Aligning...............................................................................................................................................................................................................................................................................................................................................................................................................................................................5463
2 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5468
2.1 Carpet..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5468
2.1.1 Carpet....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5468
2.2 Door Trim Panels, Golf from MY 04...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5470
2.2.1 Door Trim Molding.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5470
2.2.2 Driver Side Front Door Trim...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5471
2.2.3 Passenger Side Front Door Trim............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5472
2.2.4 Rear Door Trim............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5474
2.2.5 Window Crank..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5475
2.3 Door Trim Panels, Golf from MY 09...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5477
2.3.1 Door Trim Panel Decorative Trim...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5477
2.3.2 Front Door Trim Panel, 2-door Vehicles....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5478
2.3.3 Front Door Trim Panel, 4-door Vehicles....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5481
2.3.4 Front Speaker Trim........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5484
2.3.5 Rear Door Trim............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5484
2.4 Instrument Panel................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5487
2.4.1 Instrument Panel..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5487
2.4.2 Instrument Panel Crossmember..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5494
2.5 Luggage Compartment Trim........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5499
2.5.1 Luggage Compartment Side Trim.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5499
2.5.2 Rear Lock Carrier Cover...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5500
2.5.3 Storage Compartment, Luggage Compartment Cover............................................................................................................................................................................................................................................................................................................................................................................................................................................................5501
2.6 Pillar and Side Trim............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5504
2.6.1 C-Pillar Trim.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5504
2.6.2 Center A-Pillar Trim......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5506
2.6.3 Lower B-Pillar Trim.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5507
2.6.4 Lower A-Pillar Trim, Driver Side..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5508
2.6.5 Lower A-Pillar Trim, Passenger Side.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................5509
2.6.6 Side Trim, 2-door.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5510
2.6.7 Upper A-Pillar Trim.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5511
2.6.8 Upper B-Pillar Trim.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5513
2.7 Rear Lid Trim Panel, Golf from MY 04............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5515
2.7.1 Rear Lid Trim.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5515
2.7.2 Window Frame Trim.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5516
2.8 Rear Lid Trim Panel, Golf from MY 09............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5518
2.8.1 Rear Lid Trim.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5518
2.8.2 Window Frame Trim.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5519
2.9 Roof Trim.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5520
2.9.1 Headliner.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5520
2.9.2 Roof End Strip............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5524
2.9.3 Roof Insulation and Reinforcement.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5525
3 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5528
72 – Seat Frames............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5530
1 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5531
1.1 Front Seats.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5531
1.1.1 Backrest Release Cable, Seat with Pass-Through............................................................................................................................................................................................................................................................................................................................................................................................................................................................5531
1.1.2 Backrest release, 2-door..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5532
1.1.3 Bucket Seat Pan...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5534
1.1.4 Bucket Seat Backrest Release Cable........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5535
1.1.5 Bucket Seat Pan...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5537
1.1.6 Entry Assistance Unit Release Cable.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................5538
1.1.7 Front Seat................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5539
1.1.8 Front bucket seat backrest, removing and installing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................5543
1.1.9 Front Seat Support and Operating Lever....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5545
1.1.10 Front Bucket Seat Bracket and Operating Lever............................................................................................................................................................................................................................................................................................................................................................................................................................................................5546
1.1.11 Headrest Guides..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5547
1.1.12 Left Seat Trim...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5549
1.1.13 Left Bucket Seat Trim....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5550
1.1.14 Left Power Seat Trim.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5552
1.1.15 Left Seat Trim with Pass-Through.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5553
1.1.16 Left Front Seat Backrest.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5554
1.1.17 Lumbar Support Frame, Manual, Golf from MY 04............................................................................................................................................................................................................................................................................................................................................................................................................................................................5555
1.1.18 Lumbar Support Frame, Manual, Golf from MY 09............................................................................................................................................................................................................................................................................................................................................................................................................................................................5557
1.1.19 Lumbar Support, Power Seat...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5558
1.1.20 Lumbar Support Lever, Golf from MY 09....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5560
1.1.21 Power Forward/Back Adjustment Unit.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................5561
1.1.22 Power Seat Pan...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5563
1.1.23 Power Seat Angle Adjustment Unit.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5565
1.1.24 Power Seat Height Adjustment Unit........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5566
1.1.25 Power Seat Backrest Adjustment Motor.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5568
1.1.26 Power Seat Bracket and Support...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5568
1.1.27 Right Seat Trim..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5569
1.1.28 Right Bucket Seat Trim...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5570
1.1.29 Slider, 2-door Vehicles..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5571
1.1.30 Seat Drawer Mount........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5572
1.1.31 Trim, Right, Seat with Pass-Through......................................................................................................................................................................................................................................................................................................................................................................................................................................................................5573
1.2 Rear Seats......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5575
1.2.1 Bench Seat................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5575
1.2.2 Backrest..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5576
1.2.3 Side Upholstery with Side Airbag, 4-door..................................................................................................................................................................................................................................................................................................................................................................................................................................................................5577
1.2.4 Side Upholstery, 4-door...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5578
2 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5580
74 – Seat Upholstery, Covers................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5582
1 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5582
1.1 Front Seat Covers and Cushion...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5582
1.1.1 Front Seat Pan Covers and Cushion.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5582
1.1.2 Front Bucket Seat Cushion Cover and Cushion...............................................................................................................................................................................................................................................................................................................................................................................................................................................................5584
1.1.3 Front Seat Backrest Cover and Cushion.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5587
1.1.4 Front Bucket Seat Backrest................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5592
1.2 Rear Seats Covers and Cushion...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5595
1.2.1 Bench Seat Cover and Cushion..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5595
1.2.2 Backrest Covers and Cushion...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5597
1.2.3 Pass-Through Unit with Center Armrest.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5599
2 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5601
09-Electrical Equipment.pdf (p.5606-6249)...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5606
09-01 Electrical Equipment General Information..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5606
27 – Battery, Starter, Generator, Cruise Control............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5612
1 Battery...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5612
1.1 Battery General Information.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5612
1.2 Types of Batteries..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5612
1.2.1 Battery with Visual Indicator, Standard...................................................................................................................................................................................................................................................................................................................................................................................................................................................................5613
1.2.2 Battery with Visual Indicator, Enhanced...................................................................................................................................................................................................................................................................................................................................................................................................................................................................5613
1.2.3 AGM Battery...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5614
1.3 Warnings and Safety Precautions.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5614
1.3.1 Battery Safety Precautions................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5614
1.3.3 Working on Airbag System..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5616
1.4 Battery Post/Terminal...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5616
2 Battery, Checking.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5617
2.1 General Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5617
2.2 Batteries, Checking.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5617
2.2.1 Battery with Visual Indicator, Checking...................................................................................................................................................................................................................................................................................................................................................................................................................................................................5617
2.2.2 AGM Battery, Checking.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5618
2.3 Visual Inspection...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5618
2.4 Visual Display in Battery Cover, Checking.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................5619
2.4.1 3-Color Visual Indicator, Checking........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5619
2.4.2 “2 Color” Visual Indicator, Checking......................................................................................................................................................................................................................................................................................................................................................................................................................................................................5620
2.5 Battery Tester -VAS6161-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5621
2.5.2 Battery Test, Performing using Battery Tester -VAS6161-...................................................................................................................................................................................................................................................................................................................................................................................................................................................5622
2.5.3 Warranty Test, Performing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5623
2.5.4 Maintenance Test, Performing..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5623
2.5.5 Service Test, Performing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5624
2.5.7 Evaluating Test Results...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5625
2.6 Midtronics Battery Tester -MCR340VKT-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5626
2.6.1 General Information.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5626
2.6.2 Battery, Testing using Midtronics Battery Tester -MCR340VKT-..............................................................................................................................................................................................................................................................................................................................................................................................................................................5627
2.6.3 Evaluating Test Results...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5628
2.6.4 Midtronics Battery Tester -MCR340VKT-, Troubleshooting....................................................................................................................................................................................................................................................................................................................................................................................................................................................5629
2.7 Current Draw Test...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5630
3 Battery, Charging.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5632
3.1 Battery Charger -VAS5095A-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5632
3.1.1 Battery Charger -VAS5095A- Device Description.............................................................................................................................................................................................................................................................................................................................................................................................................................................................5632
3.1.2 Battery, Charging with Battery Charger -VAS5095A-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................5633
3.1.3 Severely Discharged Battery, Charging with Battery Charger -VAS5095A-.....................................................................................................................................................................................................................................................................................................................................................................................................................................5634
3.1.4 Support Mode with Battery Charger -VAS5095A-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................5635
3.1.5 Battery Charger -VAS5095A- Maintenance Charging...........................................................................................................................................................................................................................................................................................................................................................................................................................................................5637
3.2 Battery Charger -VAS5900-.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5638
3.2.1 Battery Charger -VAS5900- Device Description..............................................................................................................................................................................................................................................................................................................................................................................................................................................................5638
3.2.2 Battery, Charging with Battery Charger -VAS5900-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................5639
3.2.3 Service Charging with Battery Charger -VAS5900-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................5640
3.2.4 Severely Discharged Batteries, Charging with Battery Charger -VAS5900-....................................................................................................................................................................................................................................................................................................................................................................................................................................5643
3.2.5 Support Mode with Battery Charger -VAS5900-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................5645
3.2.6 Battery Charger -VAS5900- Maintenance Charging............................................................................................................................................................................................................................................................................................................................................................................................................................................................5647
3.3 Battery Charger -VAS5903-.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5648
3.3.1 Battery Charger -VAS5903- Device Description..............................................................................................................................................................................................................................................................................................................................................................................................................................................................5648
3.3.2 Battery, Charging with Battery Charger -VAS5903-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................5649
3.3.3 Refresh Charging with Battery Charger -VAS5903-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................5651
3.3.4 Severely Discharged Battery, Charging with Battery Charger -VAS5903-......................................................................................................................................................................................................................................................................................................................................................................................................................................5654
3.3.5 Support Mode with Battery Charger -VAS5903-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................5656
3.3.6 Battery Charger -VAS5903- Maintenance Charging............................................................................................................................................................................................................................................................................................................................................................................................................................................................5658
3.4 Battery Charger -VAS5906-.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5660
3.4.2 Battery, Charging with Battery Charger -VAS5906-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................5660
3.5 Battery Tester Charger Kit -GRX3000VAS-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5663
3.5.1 Battery Tester Charger Kit -GRX3000VAS- General Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................5663
3.5.2 Battery, Charging.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5664
3.5.3 Battery Tester Charger Kit -GRX3000VAS- Troubleshooting...................................................................................................................................................................................................................................................................................................................................................................................................................................................5666
3.6 Solar Battery Maintainer -VAS6102A-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5667
3.7 Severely Discharged Batteries...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5667
4 Cruise Control System.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5669
4.1 Cruise Control System, Activating and Deactivating..............................................................................................................................................................................................................................................................................................................................................................................................................................................................5669
5 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5670
92 – Wiper/Washer Systems...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5671
1 Washer Fluid Line Hose Connections....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5671
1.1 Windshield and Rear Window Washer System........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5671
1.2 Headlamp Washer System..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5672
2 Hoses, Repairing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5673
2.1 General Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5673
2.2 Smooth Tube, Repairing..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5673
2.3 Corrugated Tube, Repairing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5673
3 Joint-Free Wiper Blade Characteristics................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5675
4 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5676
94 – Exterior Lights, Switches..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5677
1 HID Headlamp Usage and Safety Precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5677
96 – Interior Lights, Switches..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5680
1 12 V Socket ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5680
1.1 12 V Socket , Removing and Installing...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5680
1.2 Socket Illumination Bulb -L42-, Removing and Installing.........................................................................................................................................................................................................................................................................................................................................................................................................................................................5680
2 Cigarette Lighter -U1-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5681
2.1 General Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5681
2.2 Overview - Cigarette Lighter -U1-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5682
2.3 Cigarette Lighter Socket, Removing and Installing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................5682
2.4 Cigarette Lighter Illumination Bulb -L28-, Removing and Installing..............................................................................................................................................................................................................................................................................................................................................................................................................................................5685
3 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5687
97 – Wiring.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5688
1 Vehicle Diagnosis, Testing and Information Systems....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5688
1.1 Vehicle Diagnostic Tester, Connecting...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5688
1.2 Vehicle Diagnostic Tester, Connecting, Golf MY 1998 through 2003................................................................................................................................................................................................................................................................................................................................................................................................................................................5689
2 Wiring Harness and Connector Repairs..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5690
2.1 Vehicle Electrical System, General Repair Information...........................................................................................................................................................................................................................................................................................................................................................................................................................................................5690
2.2 Wiring Harness Repair Set.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5693
2.2.1 Wiring Harness Repair Set -VAS1978-.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................5693
2.2.2 Upgrade Kit For VAS1978 -VAS1978/50-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................5693
2.2.3 Wiring Harness Repair Set -VAS1978A-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................5694
2.2.4 Release Tool Set -VAS1978/35-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5694
2.3 Tool Descriptions...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5695
2.3.1 Crimping Pliers with Insert...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5695
2.3.2 Contact Release Tools.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5696
2.3.3 Single Wire Seal Assembly Tools...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5696
2.3.4 Wiring Harness Repair Set - Wire Strippers -VAS1978/3-....................................................................................................................................................................................................................................................................................................................................................................................................................................................5696
2.3.6 Crimping Pliers - .35-2.5mm -VAS1978/1A-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................5698
2.4 Wiring Harnesses, Repairing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5699
2.4.1 Airbag and Belt Tensioner Wire Repair Information.........................................................................................................................................................................................................................................................................................................................................................................................................................................................5699
2.4.2 CAN Bus Wires, Repairing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5702
2.4.3 Antenna Wires, Replacing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5702
2.4.4 Wires with Cross Section up to 0.35 mm 2, Repairing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................5703
2.4.5 Wire Break with Single Repair Point.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................5706
2.4.6 Wire Break with Dual Repair Point.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5707
2.5 Fiber-Optic Cables, Repairing...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5709
2.5.1 Fiber-Optic Cable, Assembling.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5709
2.5.2 Fiber-Optic Cable, Disconnecting from Wiring Harness Connector............................................................................................................................................................................................................................................................................................................................................................................................................................................5714
2.6 Antenna Wires, Repairing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5715
2.6.1 Aerial Cable Repair Set -VAS6720-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5715
2.7 Contact Housings and Connectors, Repairing......................................................................................................................................................................................................................................................................................................................................................................................................................................................................5726
2.7.1 Contact Housings and Connectors, Repair Information.......................................................................................................................................................................................................................................................................................................................................................................................................................................................5726
2.7.2 Contacts in Contact Housing, Repairing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5726
2.7.3 Single Wire Seals, Installing.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5728
2.7.4 Contact Housings, Repairing Wire Terminals................................................................................................................................................................................................................................................................................................................................................................................................................................................................5729
2.8 Contact Housings, Releasing and Disassembling...................................................................................................................................................................................................................................................................................................................................................................................................................................................................5730
2.8.1 Releasing and Disassembly Contact Housings, General Information...........................................................................................................................................................................................................................................................................................................................................................................................................................................5730
2.8.2 Secondary Lock............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5730
2.8.3 Primary Lock..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5731
2.8.4 Round Connector Systems...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5732
2.8.5 Flat Connector Systems....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5732
2.8.6 Special Connector Systems.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5734
3 Contact Surface Cleaning Set -VAS6410-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5736
3.1 Contact Surface Cleaning Set -VAS6410-, Using...................................................................................................................................................................................................................................................................................................................................................................................................................................................................5736
3.1.1 Wiring Eyelets, Repairing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5736
3.1.2 Threaded Connections, Repairing...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5738
3.1.3 Battery Terminal Clamp and Battery Terminal, Cleaning.....................................................................................................................................................................................................................................................................................................................................................................................................................................................5739
3.1.4 Protecting................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5741
4 Heated Oxygen Sensor, Replacing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5742
4.1 4-Pin Heated Oxygen Sensor (HO2S), Removing and Installing......................................................................................................................................................................................................................................................................................................................................................................................................................................................5742
4.2 6-Pin Universal Oxygen Sensor, Removing and Installing..........................................................................................................................................................................................................................................................................................................................................................................................................................................................5743
4.3 Oxygen Sensor Unit Protective Pipes.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5743
5 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5745
6 Revision History......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5747
09-02 Electrical Equipment......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5751
27 – Battery, Starter, Generator, Cruise Control............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5759
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5759
1.1 Warnings and Safety Precautions.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5759
1.2 Battery, General Information....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5759
1.3 Battery Types...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5760
1.4 Battery Post/Terminal...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5760
1.5 Battery, Testing................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5761
1.6 Battery, Charging...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5761
1.7 B+ Cable Mount on Generator.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5761
1.8 Cruise Control System...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5762
1.9 Generator.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5762
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5763
2.1 Overview - Engine Compartment Battery...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5763
2.2 Generator Overview..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5764
2.3 Generator Overview..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5766
2.4 Generator Overview..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5768
2.5 Generator Overview..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5769
2.6 Starter Overview................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5770
2.7 Starter Overview................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5771
2.8 Starter Overview................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5772
2.9 Starter Overview................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5773
2.10 Starter Overview...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5774
2.11 Starter Overview...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5775
2.12 Starter Overview...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5776
2.13 Voltage Stabilizer -J532-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5776
3 Diagnosis and Testing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5777
3.1 Generator, Checking.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5777
3.2 Ribbed Belt, Checking...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5777
3.3 Starter, Checking...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5777
4 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5778
4.1 Battery, Disconnecting and Connecting...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5778
4.2 Battery.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5780
4.3 Starter.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5781
4.4 Starter.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5783
4.5 Starter.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5785
4.6 Starter.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5788
4.7 Starter.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5789
4.8 Starter.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5792
4.9 Starter.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5794
4.10 Generator......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5797
4.11 Generator......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5800
4.12 Generator......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5803
4.13 Generator......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5808
4.14 Voltage Regulator, Bosch.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5810
4.15 Voltage Regulator, Valeo.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5811
4.16 Ribbed Belt Pulley Without Freewheel...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5812
4.17 Ribbed Belt Pulley with Freewheel, Bosch.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................5813
4.18 Ribbed Belt Pulley with Freewheel, Valeo.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................5814
4.19 Voltage Stabilizer -J532-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5816
5 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5817
90 – Instruments............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5819
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5819
1.1 Instrument Cluster General Information..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5819
1.2 Service Interval Display, Resetting.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5819
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5820
2.1 Rear Side of Instrument Cluster, Description....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5820
2.2 Instrument Cluster Connector Assignment.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5820
2.3 Warning Lamp Symbols In Instrument Panel Insert.................................................................................................................................................................................................................................................................................................................................................................................................................................................................5820
3 Diagnosis and Testing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5823
3.1 Instrument Cluster, Replace.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5823
4 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5824
4.1 Instrument Cluster..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5824
92 – Wiper/Washer Systems...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5825
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5825
1.1 Headlamp Washer System..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5825
1.2 Hoses, Repairing................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5825
1.3 Rear Window Washer System.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5825
1.4 Rear Window Washer System.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5826
1.5 Washer Fluid Line Hose Connections..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5826
1.6 Windshield Wiper System.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5826
1.7 Windshield Washer System........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5827
1.8 Windshield and Headlamp Washer Fluid Reservoir..................................................................................................................................................................................................................................................................................................................................................................................................................................................................5827
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5828
2.1 Headlamp Washer System Overview.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5828
2.2 Rear Window Washer System Overview..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5830
2.3 Rear Window Wiper System Overview...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5831
2.4 Windshield Washer System Overview...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5831
2.5 Windshield Wiper System Overview................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5833
3 Diagnosis and Testing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5835
3.1 Headlamp Washer System Spray Nozzles, Adjusting.................................................................................................................................................................................................................................................................................................................................................................................................................................................................5835
3.2 Headlamp Washer System, Bleeding................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5835
3.3 Rain/Light Recognition Sensor, Coding...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5835
3.4 Rear Window Spray Nozzle, Adjusting.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5835
3.5 Rear Window Wiper Blade Park Position, Adjusting................................................................................................................................................................................................................................................................................................................................................................................................................................................................5835
3.6 Windshield Washer System Spray Nozzles, Adjusting...............................................................................................................................................................................................................................................................................................................................................................................................................................................................5836
3.7 Windshield Wiper Blades, Adjusting Park Position................................................................................................................................................................................................................................................................................................................................................................................................................................................................5836
3.8 Wiper Motor Alternating Park Position Function, Deactivating....................................................................................................................................................................................................................................................................................................................................................................................................................................................5837
4 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5838
4.1 Headlamp Spray Nozzle Holder....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5838
4.2 Headlamp, Spray Jet Telescoping Cylinder........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5839
4.3 Headlamp Spray Jet Telescoping Cylinder.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5840
4.4 Headlamp Washer Pump -V11-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5841
4.5 Joint-Free Windshield Wiper.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5842
4.6 Windshield and Headlamp Washer Fluid Reservoir..................................................................................................................................................................................................................................................................................................................................................................................................................................................................5843
4.6.1 Windshield and Headlamp Washer Fluid Reservoir Filler Neck................................................................................................................................................................................................................................................................................................................................................................................................................................................5843
4.6.2 Windshield and Headlamp Washer System Reservoir...........................................................................................................................................................................................................................................................................................................................................................................................................................................................5844
4.6.3 Windshield and Headlamp Washer Fluid Reservoir, GTI.......................................................................................................................................................................................................................................................................................................................................................................................................................................................5845
4.7 Windshield and Rear Window Washer Pump -V59-....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5846
4.8 Windshield Spray Nozzles........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5847
4.9 Windshield Washer Fluid Level Sensor -G33-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................5848
4.10 Windshield Wiper System........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5849
4.10.1 Windshield Wiper System..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5849
4.10.2 Plenum Chamber Cover.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5850
4.10.4 Wiper Motor..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5850
4.11 Windshield Wiper Arms..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5851
4.12 Rain/Light Recognition Sensor -G397-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5852
4.13 Rain/Light Recognition Sensor, Servicing (Manufacturer TRW)....................................................................................................................................................................................................................................................................................................................................................................................................................................................5855
4.14 Rear Window Spray Nozzle.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5856
4.14.1 Golf.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5856
4.14.2 GTI......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5856
4.15 Rear Window Wiper Arm..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5857
4.16 Rear Window Wiper Motor -V12-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5857
4.17 Rear Window Wiper..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5858
5 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5859
94 – Exterior Lights, Switches..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5860
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5860
1.1 Access/Start Authorization, KESSY...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5860
1.2 Access/Start Authorization Control Module -J518-................................................................................................................................................................................................................................................................................................................................................................................................................................................................5861
1.3 Fog Lamps.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5861
1.4 Front Side Marker Lamp..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5861
1.5 Halogen Headlamps...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5862
1.6 Headlamp Mounting Tabs, Repairing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5862
1.7 HID Headlamps, Usage and Safety Precautions.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5863
1.8 HID Headlamp and Cornering Lamp.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5865
1.9 Rear Side Marker Lamps..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5866
1.10 Start System Button -E378-.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5866
1.11 Steering Column Switch, through 05/2010........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5867
1.12 Steering Column Combination Switch -E595-, through 05/2010.....................................................................................................................................................................................................................................................................................................................................................................................................................................................5867
1.13 Steering Column Switches, from 06/2010.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5867
1.13.1 Base Carrier for Steering Column Switches................................................................................................................................................................................................................................................................................................................................................................................................................................................................5867
1.13.2 Steering Column Combination Switch -E595-................................................................................................................................................................................................................................................................................................................................................................................................................................................................5868
1.13.3 Steering Column Electronics Control Module -J527-........................................................................................................................................................................................................................................................................................................................................................................................................................................................5868
1.13.4 Steering Column Switch...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5869
1.14 Steering Column Switches, With KESSY, from 06/2010.............................................................................................................................................................................................................................................................................................................................................................................................................................................................5870
1.14.1 Base Carrier For Steering Column Switches................................................................................................................................................................................................................................................................................................................................................................................................................................................................5870
1.14.2 Electronic Steering Column Lock Control Module -J764-....................................................................................................................................................................................................................................................................................................................................................................................................................................................5870
1.14.3 Steering Column Combination Switch -E595-................................................................................................................................................................................................................................................................................................................................................................................................................................................................5870
1.14.4 Steering Column Electronics Control Module -J527-........................................................................................................................................................................................................................................................................................................................................................................................................................................................5870
1.14.5 Steering Column Switch...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5871
1.15 Turn Signal and Entry Lamp in Exterior Mirror..................................................................................................................................................................................................................................................................................................................................................................................................................................................................5872
1.16 Parking Aid....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5873
1.16.1 General Information......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5873
1.16.2 Parking Aid Control Module -J446-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5874
1.16.3 Parking Aid Control Module -J446-, Coding................................................................................................................................................................................................................................................................................................................................................................................................................................................................5874
1.16.4 Parking Aid Control Module -J446- Connector Assignment...................................................................................................................................................................................................................................................................................................................................................................................................................................................5874
1.16.5 Parking Aid Sensors......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5874
1.16.6 Parking Aid Sensor, Replacing............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5875
1.16.7 Sensor, Painting.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5875
1.16.8 Parking Aid Button -E266-................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5875
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5876
2.1 Access/Start Authorization Overview.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5876
2.2 Fog Lamp, Golf Overview.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5879
2.3 Fog Lamp, GTI Overview..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5880
2.4 Halogen Headlamps Overview......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5880
2.5 Headlamp Reflector Adjustment Solenoid..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5882
2.6 HID Headlamp and Cornering Lamp Overview........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5883
2.7 HID Headlamp and Cornering Lamp Overview........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5884
2.8 Rear Lid Tail Lamps Overview....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5885
2.9 Side Panel Tail Lamps Overview..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5886
2.10 Steering Column Switch, through 05/2010, Overview..............................................................................................................................................................................................................................................................................................................................................................................................................................................................5888
2.11 Steering Column Switch, from 06/2010, Overview.................................................................................................................................................................................................................................................................................................................................................................................................................................................................5889
2.12 Steering Column Switch with KESSY, from 06/2010, Overview......................................................................................................................................................................................................................................................................................................................................................................................................................................................5890
2.13 Overview - Parking Aid.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5893
2.14 Overview - Parking Aid.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5894
3 Diagnosis and Testing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5897
3.1 Access/Start Authorization Antennae and Sensors, Checking.......................................................................................................................................................................................................................................................................................................................................................................................................................................................5897
3.1.1 Access/Start System Antenna in Rear Bumper -R136-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................5898
3.1.2 Driver Access/Start System Antenna -R134-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................5898
3.1.3 Driver Exterior Door Handle Touch Sensor -G415-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................5898
3.1.4 Front Passenger Access/Start System Antenna -R135-........................................................................................................................................................................................................................................................................................................................................................................................................................................................5898
3.1.5 Front Passenger Exterior Door Handle Touch Sensor -G416-..................................................................................................................................................................................................................................................................................................................................................................................................................................................5898
3.1.6 Access/Start System Antenna 1 in Vehicle Interior -R138-..................................................................................................................................................................................................................................................................................................................................................................................................................................................5898
3.1.7 Access/Start System Antenna in Luggage Compartment -R137-.................................................................................................................................................................................................................................................................................................................................................................................................................................................5898
3.2 Access/Start Authorization Control Module -J518-, Coding........................................................................................................................................................................................................................................................................................................................................................................................................................................................5898
3.3 Cornering Lamp and Headlamp Range Control Module -J745-, Coding.................................................................................................................................................................................................................................................................................................................................................................................................................................................5898
3.4 Fog Lamps, Adjusting............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5899
3.5 Headlamp, Adjusting.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5899
3.6 Headlamps, Correcting Installation Position.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5899
3.7 Headlamp Power Output Stage, Checking...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5900
3.8 Headlamp Range Control Positioning Motor, Checking..............................................................................................................................................................................................................................................................................................................................................................................................................................................................5900
3.9 Headlamp Reflector Adjustment Solenoid, Checking................................................................................................................................................................................................................................................................................................................................................................................................................................................................5901
3.10 HID Headlamp, Adjusting........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5901
3.11 High-mounted Brake Lamp Bulb -M25-, Checking...................................................................................................................................................................................................................................................................................................................................................................................................................................................................5901
3.12 Ignition Switch, through 05/2010, Checking.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5901
3.13 Ignition Switch, from 06/2010, Checking........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5901
3.14 Steering Column Electronics Control Module -J527-, through 05/2010, Coding.....................................................................................................................................................................................................................................................................................................................................................................................................................................5901
3.15 Steering Column Electronics Control Module -J527-, from 06/2010, Coding........................................................................................................................................................................................................................................................................................................................................................................................................................................5901
3.16 Steering Column Electronics Control Module -J527-, With KESSY, from 06/2010, Coding............................................................................................................................................................................................................................................................................................................................................................................................................................5901
3.17 Electronic Steering Column Lock Control Module -J764-, With KESSY, from 06/2010, Coding........................................................................................................................................................................................................................................................................................................................................................................................................................5901
3.18 Steering Column Combination Switch -E595-, Checking............................................................................................................................................................................................................................................................................................................................................................................................................................................................5902
3.19 Swivel Module Position Sensor, Checking........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5902
3.20 Front Parking Aid Sensor, Checking.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5902
3.21 Rear Parking Aid Sensor, Checking..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5902
3.22 Parking Aid Warning Buzzer.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5902
3.22.1 Front Parking Aid Warning Buzzer -H22- Volume, Adjusting.................................................................................................................................................................................................................................................................................................................................................................................................................................................5902
3.22.2 Front Parking Aid Warning Buzzer -H22- Tone, Adjusting...................................................................................................................................................................................................................................................................................................................................................................................................................................................5903
3.22.3 Rear Parking Aid Warning Buzzer -H15- Volume, Adjusting..................................................................................................................................................................................................................................................................................................................................................................................................................................................5903
3.22.4 Rear Parking Aid Warning Buzzer -H15- Tone, Adjusting....................................................................................................................................................................................................................................................................................................................................................................................................................................................5903
4 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5905
4.1 Access/Start Authorization Antennas and Sensors.................................................................................................................................................................................................................................................................................................................................................................................................................................................................5905
4.1.1 Access/Start System Antenna in Rear Bumper -R136-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................5906
4.1.2 Access/Start System Antenna 1 in Vehicle Interior -R138-..................................................................................................................................................................................................................................................................................................................................................................................................................................................5906
4.1.3 Driver Outside Door Handle................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5907
4.1.4 Access/Start System Antenna in Luggage Compartment -R137-.................................................................................................................................................................................................................................................................................................................................................................................................................................................5907
4.1.5 Passenger Outside Door Handle.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5908
4.2 Access/Start Authorization Control Module -J518-................................................................................................................................................................................................................................................................................................................................................................................................................................................................5908
4.3 Driver Entry Lamp in Exterior Rearview Mirror -W52-/Front Passenger Entry Lamp in Exterior Rearview Mirror -W53-................................................................................................................................................................................................................................................................................................................................................................................................5909
4.4 Entry Lamp in Exterior Mirror, Bulb.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5910
4.5 Exterior Mirror Turn Signal Lamps...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5911
4.6 Fog Lamps.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5911
4.6.1 Fog Lamp Golf.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5911
4.6.2 Fog Lamp Bulb and Static Cornering Lamp Golf..............................................................................................................................................................................................................................................................................................................................................................................................................................................................5912
4.6.3 Fog Lamp, GTI.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5913
4.6.4 Fog Lamp Bulb and Static Cornering Lamp, GTI..............................................................................................................................................................................................................................................................................................................................................................................................................................................................5914
4.7 Front Side Marker Lamp..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5915
4.8 Front Side Marker Lamp Bulb.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5916
4.9 Halogen Headlamps...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5917
4.9.1 Center Headlamp Mounting Tab, Repairing...................................................................................................................................................................................................................................................................................................................................................................................................................................................................5917
4.9.2 Front Turn Signal Bulb....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5918
4.9.3 Halogen Headlamps.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5919
4.9.4 Headlamp Range Control Positioning Motor, Hella...........................................................................................................................................................................................................................................................................................................................................................................................................................................................5921
4.9.5 Headlamp Range Control Positioning Motor, Valeo...........................................................................................................................................................................................................................................................................................................................................................................................................................................................5923
4.9.6 High Beam Headlamp Bulb and Daytime Running Lamp Bulb.....................................................................................................................................................................................................................................................................................................................................................................................................................................................5925
4.9.7 Inner Headlamp Mounting Tab, Repairing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5926
4.9.8 Low Beam Headlamp Bulb....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5927
4.9.9 Outer Headlamp Mounting Tab, Repairing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5928
4.9.10 Parking Lamp Bulb........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5929
4.10 HID Headlamp and Cornering Lamp................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5930
4.10.1 Cornering Lamp and Headlamp Range Control Module -J745-..................................................................................................................................................................................................................................................................................................................................................................................................................................................5930
4.10.2 Daytime Running Lamp and Position Lamp LED Module -L176-/-L177-..........................................................................................................................................................................................................................................................................................................................................................................................................................................5931
4.10.3 Daytime Running Lamp and Position Lamp LED Module -L176-/-L177-..........................................................................................................................................................................................................................................................................................................................................................................................................................................5931
4.10.4 Headlamps................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5933
4.10.5 Headlamp Power Output Stage -J667-/-J668-................................................................................................................................................................................................................................................................................................................................................................................................................................................................5935
4.10.6 Headlamp Range Control Positioning Motor.................................................................................................................................................................................................................................................................................................................................................................................................................................................................5936
4.10.7 Headlamp Reflector Adjustment Solenoid -N395-/-N396-.....................................................................................................................................................................................................................................................................................................................................................................................................................................................5936
4.10.8 HID Bulb.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5936
4.10.9 HID Lamp Ballast -J426-/-J427-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5938
4.10.10 Level Control System Sensor.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5939
4.10.11 Parking Lamp Bulb.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5939
4.10.12 Turn Signal Bulb........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5940
4.11 High-mounted Brake Lamp Bulb -M25-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5942
4.11.1 Golf.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5942
4.11.2 GTI, through 05/2009.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5944
4.11.3 GTI, from 06/2009........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5945
4.12 Ignition Switch and Lock Cylinder, through 05/2010.............................................................................................................................................................................................................................................................................................................................................................................................................................................................5946
4.12.1 Steering Lock Housing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5946
4.12.2 Lock Cylinder............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5947
4.12.3 Ignition Switch..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5949
4.12.4 Ignition Switch Key Lock Solenoid -N376-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................5950
4.13 Ignition Switch and Lock Cylinder, from 06/2010................................................................................................................................................................................................................................................................................................................................................................................................................................................................5951
4.13.1 Steering Lock Housing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5951
4.13.2 Lock Cylinder............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5951
4.13.3 Ignition Switch..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5953
4.13.4 Ignition Switch Key Lock Solenoid -N376-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................5954
4.14 License Plate Lamp.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5955
4.14.1 License Plate Lamp Attached by Screws....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5955
4.14.2 Bulb, License Plate Lamp Attached by Screws..............................................................................................................................................................................................................................................................................................................................................................................................................................................................5956
4.14.3 License Plate Lamp Attached by Clips.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5957
4.14.4 Bulb, License Plate Lamp Attached by Clips...............................................................................................................................................................................................................................................................................................................................................................................................................................................................5958
4.15 Start System Button -E378-.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5958
4.16 Steering Column Switch, through 05/2010........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5959
4.16.1 Steering Column Switch Components, Removal and Installation Sequence.....................................................................................................................................................................................................................................................................................................................................................................................................................................5959
4.16.2 Airbag Spiral Spring/Return Spring with Slip Ring -F138-.................................................................................................................................................................................................................................................................................................................................................................................................................................................5960
4.16.3 Steering Column Switch Base Plate........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5961
4.16.4 Steering Column Electronics Control Module -J527-........................................................................................................................................................................................................................................................................................................................................................................................................................................................5963
4.16.5 Turn Signal Switch -E2-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5964
4.16.6 Windshield Wiper Switch -E-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5965
4.17 Steering Column Switch, Without KESSY, from 06/2010............................................................................................................................................................................................................................................................................................................................................................................................................................................................5966
4.17.1 Steering Column Switch Components, Removal and Installation Sequence.....................................................................................................................................................................................................................................................................................................................................................................................................................................5966
4.17.2 Steering Column Electronics Control Module -J527-, Valeo.................................................................................................................................................................................................................................................................................................................................................................................................................................................5967
4.17.3 Steering Column Electronics Control Module -J527-, Kostal................................................................................................................................................................................................................................................................................................................................................................................................................................................5968
4.17.4 Steering Column Combination Switch -E595-, Valeo.........................................................................................................................................................................................................................................................................................................................................................................................................................................................5969
4.17.5 Steering Column Combination Switch -E595-, Kostal........................................................................................................................................................................................................................................................................................................................................................................................................................................................5970
4.17.6 Steering Column Switch Base Carrier, Valeo...............................................................................................................................................................................................................................................................................................................................................................................................................................................................5970
4.17.7 Steering Column Switch Base Carrier, Kostal..............................................................................................................................................................................................................................................................................................................................................................................................................................................................5972
4.18 Steering Column Switch, With KESSY, from 06/2010...............................................................................................................................................................................................................................................................................................................................................................................................................................................................5974
4.18.1 Steering Column Switch Components, Removal and Installation Sequence.....................................................................................................................................................................................................................................................................................................................................................................................................................................5974
4.18.2 Steering Column Electronics Control Module -J527-, Valeo.................................................................................................................................................................................................................................................................................................................................................................................................................................................5975
4.18.3 Steering Column Electronics Control Module -J527-, Kostal................................................................................................................................................................................................................................................................................................................................................................................................................................................5977
4.18.4 Steering Column Combination Switch -E595-, Valeo.........................................................................................................................................................................................................................................................................................................................................................................................................................................................5978
4.18.5 Steering Column Combination Switch -E595-, Kostal........................................................................................................................................................................................................................................................................................................................................................................................................................................................5979
4.18.6 Steering Column Switch Base Carrier, Valeo...............................................................................................................................................................................................................................................................................................................................................................................................................................................................5979
4.18.7 Steering Column Switch Base Carrier, Kostal..............................................................................................................................................................................................................................................................................................................................................................................................................................................................5981
4.18.8 Electronic Steering Column Lock Control Module -J764-....................................................................................................................................................................................................................................................................................................................................................................................................................................................5983
4.19 Tail Lamps.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5984
4.19.1 Brake/Tail Lamp and Turn Signal Lamp, Bulbs..............................................................................................................................................................................................................................................................................................................................................................................................................................................................5984
4.19.2 Rear Lid Tail Lamps......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5985
4.19.3 Side Panel Tail Lamps....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5986
4.19.4 Side Panel Tail Lamp Bulb Holder.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5987
4.19.5 Tail Lamp Bulb Holder in Rear Lid........................................................................................................................................................................................................................................................................................................................................................................................................................................................................5987
4.19.6 Tail Lamp and Brake Lamp in Rear Lid, Bulbs..............................................................................................................................................................................................................................................................................................................................................................................................................................................................5988
4.20 Parking Aid Control Module -J446-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................5989
4.21 Front Parking Aid Sensor.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5989
4.22 Front Parking Aid Sensor.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5991
4.23 Rear Parking Aid Sensor, Removing and Installing...............................................................................................................................................................................................................................................................................................................................................................................................................................................................5993
4.24 Parking Aid Warning Buzzer.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5995
4.24.1 Front Parking Aid Warning Buzzer -H22-...................................................................................................................................................................................................................................................................................................................................................................................................................................................................5995
4.24.2 Rear Parking Aid Warning Buzzer -H15-....................................................................................................................................................................................................................................................................................................................................................................................................................................................................5996
4.25 Parking Aid Button -E266-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5996
5 LED Tail Lamps........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5997
5.1 General Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5997
5.2 Side Panel LED Tail Lamps.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5997
5.2.1 Side Panel LED Tail Lamps Assembly Overview...............................................................................................................................................................................................................................................................................................................................................................................................................................................................5997
5.2.2 Side Panel LED Tail Lamps, Removing and Installing........................................................................................................................................................................................................................................................................................................................................................................................................................................................5998
5.2.3 Turn Signal Bulb, Removing and Installing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................5999
5.2.4 Side Panel LED Tail Lamps, Checking.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6000
5.3 Rear Lid Tail Lamps with LEDs...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6000
5.3.1 Rear Lid Tail Lamps with LEDs Assembly Overview...........................................................................................................................................................................................................................................................................................................................................................................................................................................................6000
5.3.2 Rear Lid Tail Lamps with LEDs, Removing and Installing....................................................................................................................................................................................................................................................................................................................................................................................................................................................6002
5.3.3 Right Back-Up Lamp Bulb, Removing and Installing..........................................................................................................................................................................................................................................................................................................................................................................................................................................................6004
5.3.4 Rear Lid Tail Lamps with LEDs, Checking...................................................................................................................................................................................................................................................................................................................................................................................................................................................................6005
6 Parallel Parking Assistance...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6006
6.1 General Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6006
6.2 Overview - Parallel Parking Assistance..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6007
6.3 Parallel Parking Assistance Control Module -J791-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................6009
6.3.1 Parallel Parking Assistance Control Module -J791-, Removing and Installing................................................................................................................................................................................................................................................................................................................................................................................................................................6009
6.3.2 Parallel Parking Assistance Control Module -J791-, Removing and Installing, RHD...........................................................................................................................................................................................................................................................................................................................................................................................................................6009
6.3.3 Parallel Parking Assistance Control Module -J791-, Coding.................................................................................................................................................................................................................................................................................................................................................................................................................................................6010
6.3.4 Parking Aid, Adapting Optical Illustration................................................................................................................................................................................................................................................................................................................................................................................................................................................................6010
6.4 Parallel Parking Assistance Sensor..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6010
6.4.1 Parallel Parking Assistance Sensor, Removing and Installing...............................................................................................................................................................................................................................................................................................................................................................................................................................................6011
6.4.2 Parking Aid Sensor or Parallel Parking Assistance Sensor, Checking........................................................................................................................................................................................................................................................................................................................................................................................................................................6012
6.5 Parallel Parking Assistance Sensor, Removing and Installing.....................................................................................................................................................................................................................................................................................................................................................................................................................................................6013
6.5.1 Sensor, Painting..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6013
6.6 Front Parking Aid Warning Buzzer -H22-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6013
6.6.1 Front Parking Aid Warning Buzzer -H22-, Removing and Installing...........................................................................................................................................................................................................................................................................................................................................................................................................................................6013
6.6.2 Front Parking Aid Warning Buzzer -H22- Volume, Adjusting..................................................................................................................................................................................................................................................................................................................................................................................................................................................6014
6.6.3 Front Parking Aid Warning Buzzer -H22- Tone, Adjusting....................................................................................................................................................................................................................................................................................................................................................................................................................................................6014
6.7 Rear Parking Aid Warning Buzzer -H15-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6014
6.7.1 Rear Parking Aid Warning Buzzer -H15-, Removing and Installing............................................................................................................................................................................................................................................................................................................................................................................................................................................6014
6.7.2 Rear Parking Aid Warning Buzzer -H15- Volume, Adjusting...................................................................................................................................................................................................................................................................................................................................................................................................................................................6014
6.7.3 Rear Parking Aid Warning Buzzer -H15- Tone, Adjusting.....................................................................................................................................................................................................................................................................................................................................................................................................................................................6015
6.8 Parallel Parking Assistance Button -E581-.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6015
6.8.1 Parallel Parking Assistance Button -E581-, Removing and Installing........................................................................................................................................................................................................................................................................................................................................................................................................................................6015
6.8.2 Parallel Parking Assistance Button -E581-, Checking.......................................................................................................................................................................................................................................................................................................................................................................................................................................................6015
7 Rearview Camera.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6016
7.1 General Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6016
7.2 Overview - Rearview Camera System...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6016
7.3 Rearview Camera Housing, Removing and Installing................................................................................................................................................................................................................................................................................................................................................................................................................................................................6017
7.3.1 Pivoting Emblem with Rearview Camera Housing and Pivoting Motor, Removing from Rear Lid and Installing....................................................................................................................................................................................................................................................................................................................................................................................................6018
7.3.2 Rearview Camera Housing with Pivoting Motor, Removing from Pivoting Emblem and Installing.................................................................................................................................................................................................................................................................................................................................................................................................................6020
7.3.3 Rearview Camera Housing, Disconnecting from Pivoting Motor................................................................................................................................................................................................................................................................................................................................................................................................................................................6021
7.3.4 Rearview Camera, Removing and Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................................6022
8 High Beam Assist......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6023
8.1 General Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6023
8.2 Automatic High Beam Assist Control Module -J844-................................................................................................................................................................................................................................................................................................................................................................................................................................................................6023
8.2.1 Automatic High Beam Assist Control Module -J844-, Removing and Installing.................................................................................................................................................................................................................................................................................................................................................................................................................................6023
8.2.2 Automatic High Beam Assist Control Module -J844-, Coding..................................................................................................................................................................................................................................................................................................................................................................................................................................................6024
8.3 Light Recognition Sensor -G399-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6024
8.3.1 Light Recognition Sensor -G399-, Removing and Installing..................................................................................................................................................................................................................................................................................................................................................................................................................................................6024
9 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6025
96 – Interior Lights, Switches..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6027
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6027
1.1 Anti-Theft Alarm System.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6027
1.1.1 General Information.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6027
1.1.2 Alarm Horn -H12-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6028
1.1.3 Anti-Theft Alarm System, Activating and Deactivating......................................................................................................................................................................................................................................................................................................................................................................................................................................................6028
1.1.4 Anti-theft Alarm System Sensor -G578-.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................6028
1.1.5 Central Locking and Anti-theft Alarm System Antenna -R47-.................................................................................................................................................................................................................................................................................................................................................................................................................................................6029
1.1.6 Interior Monitoring Deactivation Switch -E267- and Vehicle Inclination Sensor Deactivation Button -E360-..................................................................................................................................................................................................................................................................................................................................................................................................6029
1.1.7 Interior Monitoring Sensor -G273-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6029
1.1.8 Vehicle Inclination Sensor -G384-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6029
1.2 Anti-Theft Immobilizer Control Module -J362-....................................................................................................................................................................................................................................................................................................................................................................................................................................................................6030
1.3 Engine Compartment Lamps and Switches...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6031
1.4 Front Door Lamps and Switches...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6031
1.4.1 Central Locking -SAFE- Indicator Lamp -K133-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................6031
1.4.2 Driver Interior Locking Button -E308-.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................6031
1.4.3 Driver Window Regulator Switch Module.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................6031
1.4.4 Front Door Lock Components................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6032
1.4.5 Mirror Adjustment Switch Module, Driver Side..............................................................................................................................................................................................................................................................................................................................................................................................................................................................6032
1.5 High Tone Horn -H2-/Low Tone Horn -H7-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6033
1.6 Instrument Panel Lamps and Switches.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6033
1.6.1 Emergency Flasher Switch -E3-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6033
1.6.2 Front Passenger Airbag -Disabled- Indicator Lamp -K145-...................................................................................................................................................................................................................................................................................................................................................................................................................................................6033
1.6.3 Front Passenger Airbag Deactivation Key Switch -E224-.....................................................................................................................................................................................................................................................................................................................................................................................................................................................6033
1.6.4 Glove Compartment Lamp -W6-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6033
1.6.5 Glove Compartment Lamp Switch -E26-.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6034
1.6.6 Headlamp Range Control Adjuster -E102- and Instrument Panel Illumination Dimmer Switch -E20-..............................................................................................................................................................................................................................................................................................................................................................................................................6034
1.6.7 Left Footwell Lamp -W9-...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6034
1.6.8 Light Switch -E1-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6034
1.6.9 Right Footwell Lamp -W10-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6034
1.6.10 Tire Pressure Monitoring Display Button -E492-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................6034
1.7 Lost Ignition Key...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6034
1.8 Luggage Compartment Lamp -W3-...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6035
1.9 Rear Door Lock Components.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6035
1.10 Rear Lid Lock Unit -F256-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6035
1.11 Roof Trim Lamps and Switches...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6035
1.11.1 Front Interior Lamp -W1-, Vehicles Without Anti-Theft Warning System.....................................................................................................................................................................................................................................................................................................................................................................................................................................6035
1.11.2 Front Interior Lamp -W1-, Vehicles With Anti-Theft Warning System........................................................................................................................................................................................................................................................................................................................................................................................................................................6036
1.11.3 Rear Interior and Reading Lights.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6036
1.12 Switches in Center Console Storage Compartment.................................................................................................................................................................................................................................................................................................................................................................................................................................................................6036
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6037
2.1 Anti-Theft Alarm System Overview................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6037
3 Diagnosis and Testing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6039
3.1 Alarm Horn -H12-, Checking......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6039
3.2 Anti-Theft Alarm System, Adapting...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6039
3.2.1 Alarm Delay When Opening Driver Door, Adapting............................................................................................................................................................................................................................................................................................................................................................................................................................................................6039
3.2.2 Intelligent Alarm Horn Market Version, Adapting...........................................................................................................................................................................................................................................................................................................................................................................................................................................................6039
3.2.3 Interior Monitoring Sensitivity, Adapting.................................................................................................................................................................................................................................................................................................................................................................................................................................................................6039
3.2.4 Vehicle Inclination Sensor Sensitivity, Adapting..........................................................................................................................................................................................................................................................................................................................................................................................................................................................6039
3.3 Anti-Theft Immobilizer Control Module -J362-, Adapting..........................................................................................................................................................................................................................................................................................................................................................................................................................................................6040
3.4 Emergency Flasher Switch -E3-, Checking.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6040
3.5 Fazit System Test...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6040
3.6 Horns, Checking.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6040
3.7 Ignition Key, Adapting..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6040
3.8 Interior Monitoring Deactivation Switch -E267- and Vehicle Inclination Sensor Deactivation Button -E360-, Checking..............................................................................................................................................................................................................................................................................................................................................................................................6040
3.9 New Identity When Replacing All Components......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6040
3.10 Remote Key, Checking...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6040
4 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6041
4.1 Alarm Horn......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6041
4.2 Anti-theft Alarm System Sensor -G578-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6042
4.3 Anti-Theft Immobilizer Control Module -J362-....................................................................................................................................................................................................................................................................................................................................................................................................................................................................6043
4.4 Buttons in Center Console Storage Compartment...................................................................................................................................................................................................................................................................................................................................................................................................................................................................6044
4.5 Front Hood Contact Switch -F266-................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6045
4.6 Front Door Lamps and Switches...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6046
4.6.1 Central Locking -SAFE- Indicator Lamp -K133-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................6046
4.6.2 Driver Interior Locking Button -E308-.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................6047
4.6.3 Driver Mirror Adjustment Switch Module....................................................................................................................................................................................................................................................................................................................................................................................................................................................................6047
4.6.4 Driver Window Regulator Switch Module.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................6047
4.6.5 Front Passenger Door Window Regulator Switch -E107-.......................................................................................................................................................................................................................................................................................................................................................................................................................................................6048
4.7 Horns...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6049
4.8 Instrument Panel Lamps and Switches.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6050
4.8.1 Emergency Flasher Switch -E3-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6050
4.8.2 Front Passenger Airbag -Disabled- Indicator Lamp -K145-...................................................................................................................................................................................................................................................................................................................................................................................................................................................6051
4.8.3 Front Passenger Airbag Deactivation Key Switch -E224-.....................................................................................................................................................................................................................................................................................................................................................................................................................................................6052
4.8.4 Glove Compartment Lamp -W6-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6052
4.8.5 Glove Compartment Lamp Switch -E26-.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6054
4.8.6 Headlamp Range Control Adjuster -E102- and Instrument Panel Illumination Dimmer Switch -E20-..............................................................................................................................................................................................................................................................................................................................................................................................................6054
4.8.7 Light Switch -E1-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6054
4.8.8 Left Footwell Lamp -W9-...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6055
4.8.9 Left Footwell Lamp -W9- Bulb..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6056
4.8.10 Right Footwell Lamp -W10-................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6057
4.8.11 Right Footwell Lamp -W10- Bulb...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6057
4.8.12 Tire Pressure Monitoring Display Button -E492-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................6058
4.9 Interior Monitoring Deactivation Switch -E267- and Vehicle Inclination Sensor Deactivation Button -E360-........................................................................................................................................................................................................................................................................................................................................................................................................6058
4.10 Luggage Compartment Lamp -W3-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6059
4.11 Luggage Compartment Lamp -W3- Bulb.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6060
4.12 Rear Door Window Switches......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6061
4.13 Rear Lid Lock Unit -F256-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6061
4.14 Roof Trim Lamps and Switches...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6062
4.14.1 Front Interior Lamp -W1-, Without Anti-Theft Warning System..............................................................................................................................................................................................................................................................................................................................................................................................................................................6062
4.14.2 Front Passenger Reading Lamp -W13- and Driver Reading Lamp -W19- without Anti-Theft Warning System.......................................................................................................................................................................................................................................................................................................................................................................................................6063
4.14.3 Front Reading Lamp Buttons without Anti-Theft Warning System.............................................................................................................................................................................................................................................................................................................................................................................................................................................6064
4.14.4 Front Interior Lamp -W1-, with Anti-Theft Warning System.................................................................................................................................................................................................................................................................................................................................................................................................................................................6064
4.14.5 Front Passenger Reading Lamp -W13- and Driver Reading Lamp -W19- with Anti-Theft Warning System..........................................................................................................................................................................................................................................................................................................................................................................................................6065
4.14.6 Front Reading Lamp Buttons With Anti-Theft Warning System................................................................................................................................................................................................................................................................................................................................................................................................................................................6066
4.14.7 Illuminated Vanity Mirror Lamps..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6066
4.14.8 Illuminated Vanity Mirror Bulb...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6067
4.14.9 Rear Interior and Reading Lamps..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6067
4.14.10 Rear Interior and Reading Light Bulbs...................................................................................................................................................................................................................................................................................................................................................................................................................................................................6068
4.14.11 Sunroof Button -E325- without Anti-Theft Warning System.................................................................................................................................................................................................................................................................................................................................................................................................................................................6069
4.14.12 Sunroof Button -E325- with Anti-Theft Warning System....................................................................................................................................................................................................................................................................................................................................................................................................................................................6069
5 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6070
97 – Wiring.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6071
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6071
1.1 Data Bus On Board Diagnostic Interface -J533-, Gateway..........................................................................................................................................................................................................................................................................................................................................................................................................................................................6071
1.2 Driver Door Control Module -J386-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6072
1.3 Front Passenger Door Control Module -J387-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6072
1.4 Left Rear Door Control Module -J388-............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6073
1.5 Right Rear Door Control Module -J389-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6073
1.6 Towing Recognition Control Module -J345-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6073
1.7 Vehicle Diagnosis, Testing and Information Systems..............................................................................................................................................................................................................................................................................................................................................................................................................................................................6074
1.8 Vehicle Electrical System Control Module -J519-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................6074
1.9 Wiring Harness and Connector Repairs............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6076
2 Specifications........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6077
2.1 Left E-box in Engine Compartment Fastener Tightening Specifications.............................................................................................................................................................................................................................................................................................................................................................................................................................................6077
3 Diagnosis and Testing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6078
3.1 Acoustic Acknowledgement when Unlocking.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6078
3.2 Acoustic Acknowledgement when Locking, Adapting.................................................................................................................................................................................................................................................................................................................................................................................................................................................................6078
3.3 Automatic Unlocking when Key Removed, Adapting..................................................................................................................................................................................................................................................................................................................................................................................................................................................................6078
3.4 Automatic Locking at 15 km/h, Adapting..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6078
3.5 Blinking Cycle during Comfort Blinking, Adapting................................................................................................................................................................................................................................................................................................................................................................................................................................................................6079
3.6 Comfort Locking Confirmation, Adapting..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6079
3.7 Comfort Operation via Radio-Frequency Remote, Adapting..........................................................................................................................................................................................................................................................................................................................................................................................................................................................6079
3.8 Coming Home Time, Adapting......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6079
3.9 Control Modules.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6079
3.9.1 Driver Door Control Module -J386-, Coding.................................................................................................................................................................................................................................................................................................................................................................................................................................................................6079
3.9.2 Front Passenger Door Control Module -J387-, Coding........................................................................................................................................................................................................................................................................................................................................................................................................................................................6079
3.9.3 Left Rear Door Control Module -J388-, Coding..............................................................................................................................................................................................................................................................................................................................................................................................................................................................6079
3.9.4 Right Rear Door Control Module -J389-, Coding.............................................................................................................................................................................................................................................................................................................................................................................................................................................................6079
3.9.5 Towing Recognition Control Module -J345-, Coding..........................................................................................................................................................................................................................................................................................................................................................................................................................................................6080
3.9.6 Towing Recognition Control Module -J345- Software, Adapting...............................................................................................................................................................................................................................................................................................................................................................................................................................................6080
3.10 Data Bus On Board Diagnostic Interface, Gateway................................................................................................................................................................................................................................................................................................................................................................................................................................................................6080
3.10.1 Data Bus On Board Diagnostic Interface, Coding...........................................................................................................................................................................................................................................................................................................................................................................................................................................................6080
3.10.2 Checking Bus Activity....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6080
3.10.3 Checking Bus Participants................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6080
3.11 Data Bus On Board Diagnostic Interface -J533-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................6080
3.12 Factory Mode, Deactivating.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6080
3.13 Footwell Light Dimmer Value, Adapting..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6080
3.14 Leaving Home Time, Adapting....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6081
3.15 Output Diagnostic Test Mode (D) of Vehicle Electrical System Control Module -J519-.............................................................................................................................................................................................................................................................................................................................................................................................................................6081
3.16 Remote Control Key, Adapting...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6082
3.17 Single Door Opening, Adapting..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6082
3.18 Vehicle Electrical System Control Module -J519-, Coding........................................................................................................................................................................................................................................................................................................................................................................................................................................................6082
3.19 Visual Acknowledgment for Locking, Adapting....................................................................................................................................................................................................................................................................................................................................................................................................................................................................6082
4 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6083
4.1 Data Bus On Board Diagnostic Interface -J533-...................................................................................................................................................................................................................................................................................................................................................................................................................................................................6083
4.2 Driver Door Control Module -J386-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6084
4.3 E-Box Fuse Panel................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6084
4.4 Front Passenger Door Control Module -J387-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6084
4.5 Instrument Panel Fuse Panel.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6084
4.6 Left Engine Compartment E-Box...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6085
4.7 Left Rear Door Control Module -J388-............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6089
4.8 Relay Carrier In Left Instrument Panel..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6089
4.9 Relay Carrier on Vehicle Electrical System Control Module -J519-................................................................................................................................................................................................................................................................................................................................................................................................................................................6091
4.10 Right Rear Door Control Module -J389-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6092
4.11 Towing Recognition Control Module -J345-.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6092
4.12 Vehicle Electrical System Control Module -J519-................................................................................................................................................................................................................................................................................................................................................................................................................................................................6093
5 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6095
6 Revision History......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6096
09-03 Electrical System E-Golf..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6100
93 – Electric Drive.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6104
1 High Voltage System Safety Precautions................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6104
2 Clean Working Conditions When Working on High Voltage System..........................................................................................................................................................................................................................................................................................................................................................................................................................................................6110
3 High Voltage System, De-Energizing....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6111
4 High Voltage System, Turning Back On..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6112
5 Component Location Overview - High Voltage Components.................................................................................................................................................................................................................................................................................................................................................................................................................................................................6113
6 High Voltage Technology Description...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6115
6.1 High Voltage Vehicle Drives.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6115
6.1.1 General Information.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6115
6.1.2 Driving Modes.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6115
6.1.3 Regenerating..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6115
7 High Volt Battery.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6117
7.1 General Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6117
7.2 Overview - High Voltage Battery.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6117
7.3 High Voltage Battery, Removing and Installing...................................................................................................................................................................................................................................................................................................................................................................................................................................................................6118
7.4 High Voltage Battery 1 -AX2-/High Voltage Battery 2 -AX3-, Checking.............................................................................................................................................................................................................................................................................................................................................................................................................................................6125
8 Electric Drive Power and Control Electronics..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6126
8.1 General Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6126
8.2 Electric Drive Power and Control Electronics, Checking..........................................................................................................................................................................................................................................................................................................................................................................................................................................................6126
8.3 Electric Drive Output and Control Electronics, Removing and Installing..........................................................................................................................................................................................................................................................................................................................................................................................................................................6127
9 Electro-Drive Drive Motor.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6131
9.1 General Information.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6131
9.2 Electric Drive Motor, Removing and Installing...................................................................................................................................................................................................................................................................................................................................................................................................................................................................6131
9.3 Electro-Drive Drive Motor, Replacing............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6138
9.4 Electro-Drive Drive Motor, Calibrating..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6139
9.5 Transmission, Removing and Installing...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6139
10 High Voltage Cables..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6140
10.1 General Information............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6140
10.2 Component Location Overview - High Voltage Cables..............................................................................................................................................................................................................................................................................................................................................................................................................................................................6141
10.3 Drive Motor High Voltage Wiring Harness, Removing and Installing...............................................................................................................................................................................................................................................................................................................................................................................................................................................6143
11 High Voltage Cooling System..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6144
11.1 Component Location Overview - High Voltage System Cooling......................................................................................................................................................................................................................................................................................................................................................................................................................................................6144
12 Battery Chargers.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6145
12.1 High Voltage Battery Charger 3, Removing and Installing........................................................................................................................................................................................................................................................................................................................................................................................................................................................6145
13 High Voltage Battery Heat Exchanger..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6147
14 High voltage heater (PTC)............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6148
15 Immediate upload button..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6149
16 Driving Program Button...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6150
17 Electric A/C Compressor..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6151
18 Potential Equalization Cables........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6152
18.1 Potential Equalization Cable on High Voltage Battery 1 -AX2- in Luggage Compartment, Removing and Installing...................................................................................................................................................................................................................................................................................................................................................................................................6152
18.2 Potential Equalization Cable on Electric Drive Power and Control Electronics -JX1-, Removing and Installing....................................................................................................................................................................................................................................................................................................................................................................................................6153
18.3 Electro-Drive Drive Motor -V141- Potential Equalization Cable, Removing and Installing.........................................................................................................................................................................................................................................................................................................................................................................................................................6153
18.4 High Voltage Battery 2 -AX3- Potential Equalization Cable under Floor Panel, Removing and Installing...........................................................................................................................................................................................................................................................................................................................................................................................................6153
18.5 Electrical A/C Compressor -V470- Potential Equalization Cable, Removing and Installing.........................................................................................................................................................................................................................................................................................................................................................................................................................6154
18.6 High Voltage Battery Charger 2 -AX5- Potential Equalization Cable, Removing and Installing.....................................................................................................................................................................................................................................................................................................................................................................................................................6154
18.7 High Voltage Battery Charger 1 -AX4- Potential Equalization Cable, Removing and Installing.....................................................................................................................................................................................................................................................................................................................................................................................................................6155
18.8 Potential Equalization Cable Engine Support, Removing and Installing...........................................................................................................................................................................................................................................................................................................................................................................................................................................6155
18.9 Connection and Junction Box 1 -SX1- Potential Equalization Cable Bracket, Removing and Installing, High Voltage Network Junction...............................................................................................................................................................................................................................................................................................................................................................................6156
18.10 Connection and Junction Box 1 -SX1- Potential Equalization Cable, Removing and Installing, High Voltage Network Junction......................................................................................................................................................................................................................................................................................................................................................................................6156
18.11 High Voltage Heater (PTC) -Z115- Potential Equalization Cable.................................................................................................................................................................................................................................................................................................................................................................................................................................................6157
18.12 High Voltage Battery Charger 3 -AX6- Potential Equalization Cable, Removing and Installing....................................................................................................................................................................................................................................................................................................................................................................................................................6157
18.13 High Voltage Charge Network Distributor -SX4- Potential Equalization Cable, Removing and Installing...........................................................................................................................................................................................................................................................................................................................................................................................................6157
18.14 Electric Drive Power and Control Electronics -JX1- Potential Equalization Cable Bracket Engine Support, Removing and Installing...............................................................................................................................................................................................................................................................................................................................................................................6158
18.15 Overview - Potential Equalization Cable.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6158
19 Special Tools........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6159
20 Revision History.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6162
09-04 Communication.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6166
91 – Communication..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6170
1 General Information...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6170
1.1 Antenna Wires, Repairing........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6170
1.2 Antenna System..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6171
1.3 Antenna Wires...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6171
1.4 Antenna and Wiring..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6171
1.5 Cellular Phones and Portable Two-Way Radios, External Antenna...................................................................................................................................................................................................................................................................................................................................................................................................................................................6171
1.6 Communication Systems...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6172
1.7 Compass System..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6172
1.8 Interference Suppression Measures...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6173
1.9 Multifunction Steering Wheel....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6173
1.10 Multimedia Control Module -J650-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6173
1.11 RCD 310 Sound System...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6175
1.12 RCD 310 Sound System, Electronic Antitheft System..............................................................................................................................................................................................................................................................................................................................................................................................................................................................6175
1.13 Premium 8 Radio System ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6178
1.14 Premium 8 Electronic Anti-Theft System.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6179
1.15 RNS 315 Radio Navigation System................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6182
1.16 RNS 315 Electronic Anti-Theft System...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6183
1.17 RNS 510 Radio Navigation System................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6185
1.18 RNS 510 Electronic Anti-Theft System...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6185
1.19 Servicing Radios and Telephones................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6187
1.20 Sound System Amplifier.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6187
1.21 Telephone Preparation, UHV Premium with Bluetooth..............................................................................................................................................................................................................................................................................................................................................................................................................................................................6188
1.22 Telephone Preparation, UHV with Audio Streaming................................................................................................................................................................................................................................................................................................................................................................................................................................................................6188
1.23 Transmitted Output, Installation Locations.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................6188
1.24 Transmitted Output Voltage Supply..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6189
1.25 Other Auxiliary Installations..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6189
1.26 Radios/Telephones with a Transmitted Output Above 10 Watts, Prerequisites......................................................................................................................................................................................................................................................................................................................................................................................................................................6189
2 Description and Operation.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6191
2.1 Antenna System..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6191
2.1.1 Without Diversity Function Overview.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6191
2.1.2 Diversity Function and Navigation System Overview.........................................................................................................................................................................................................................................................................................................................................................................................................................................................6192
2.1.3 Diversity Function, DAB Radio Reception and Navigation System.............................................................................................................................................................................................................................................................................................................................................................................................................................................6193
2.1.4 Rear Window Antenna Components Installed Locations Overview...............................................................................................................................................................................................................................................................................................................................................................................................................................................6194
2.1.5 Components From MY 2009...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6195
2.2 External Audio Source Connection................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6196
2.3 Multi Media Control Module -J650- Overview......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6196
2.4 External Audio Source Connection, Contact Assignment............................................................................................................................................................................................................................................................................................................................................................................................................................................................6197
2.5 Premium 8 Sound System..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6198
2.5.1 Overview..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6198
2.5.2 Connector Overview........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6200
2.6 RCD 310 Radio System............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6203
2.6.1 Overview..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6203
2.6.2 Connectors Overview.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6205
2.7 RNS 315 Radio Navigation System.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6208
2.7.1 Overview..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6208
2.7.2 Connector Overview........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6210
2.8 RNS 510 Radio Navigation System.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6213
2.8.1 Overview..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6213
2.8.2 Connector Overview........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6215
2.9 Speaker Overview................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6219
2.10 Telephone Preparation Overview, with Bluetooth.................................................................................................................................................................................................................................................................................................................................................................................................................................................................6220
2.11 Telephone Preparation Overview, UHV with Audio Streaming.......................................................................................................................................................................................................................................................................................................................................................................................................................................................6221
3 Diagnosis and Testing.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6223
3.1 Communication Systems, Fault Finding............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6223
3.2 Premium 8 Components, Adapting..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6223
3.3 Multifunction Steering Wheel, Troubleshooting...................................................................................................................................................................................................................................................................................................................................................................................................................................................................6223
3.4 Multifunction Steering Wheel, Adapting..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6223
3.5 Radio Components, Adapting......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6224
3.6 Radio Navigation System Components, Adapting....................................................................................................................................................................................................................................................................................................................................................................................................................................................................6224
3.7 Battery, Transmitter and Receiver Unit, Fuse and Wiring Harness Overview........................................................................................................................................................................................................................................................................................................................................................................................................................................6225
4 Removal and Installation..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6226
4.1 AM Frequency Filter.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6226
4.2 Amplifier.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6227
4.3 Antenna Module..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6228
4.4 CD Changer......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6229
4.5 Compass Magnetic Field Sensor -G197-............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6230
4.6 Control Module in Steering Wheel................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6231
4.7 Emergency Button................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6232
4.8 External Audio Source Connection -R199-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6233
4.9 FM Frequency Filter.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6233
4.10 Multimedia Control Module -J650-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6234
4.11 Radio Units and Radio Navigation...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6235
4.12 Roof Antenna...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6237
4.13 Speakers.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6239
4.13.1 Bass Speakers, Front.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6239
4.13.2 Bass Speakers, Rear......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6240
4.13.3 Treble Speakers, Front...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6240
4.13.4 Treble Speakers, Rear....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6242
4.14 Telephone Bracket..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6243
4.15 Telephone System Microphone....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6244
4.16 Telephone Transceiver..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6244
5 Special Tools.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6246
10-Wiring Diagrams and Component Locations.pdf (p.6250-7208)........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6250
004 -
Anti-Lock Brake System (ABS) with ASR , (1AS),(1AT)......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6250
1.
Anti-Lock Brake System (ABS) with ASR , (1AS),(1AT).....................................................................................................................................................................................................................................................................................................................................................................................................................................................................6250
2. Left front ABS wheel speed sensor, ABS control module, Terminal 15 power supply relay, Fuse panel B, Fuse panel C........................................................................................................................................................................................................................................................................................................................................................................................................6251
3. ASR switch, Right rear ABS wheel speed sensor, Right front ABS wheel speed sensor, Left rear ABS wheel speed sensor, ABS control module..................................................................................................................................................................................................................................................................................................................................................................................6252
4. Tire pressure monitoring display button, ABS control module, Vehicle electrical control module system....................................................................................................................................................................................................................................................................................................................................................................................................................6253
5. Parking brake indicator lamp switch, Left front brake pad wear sensor, Instrument cluster control module, Vehicle electrical control module system, Data bus on board diagnostic interface, ABS indicator lamp, Traction control indicator lamp, Brake system indicator lamp, Tire pressure monitoring display indicator lamp............................................................................................................................................................................................6254
6. Brake fluid level warning switch, Instrument cluster control module......................................................................................................................................................................................................................................................................................................................................................................................................................................................6255
005 -
Anti-Lock Brake System (ABS) with EDL and ASR and ESP , (1AS),(1AT)......................................................................................................................................................................................................................................................................................................................................................................................................................................................6256
1.
Anti-Lock Brake System (ABS) with EDL and ASR and ESP , (1AS),(1AT).....................................................................................................................................................................................................................................................................................................................................................................................................................................................6256
2. ABS control module, Terminal 15 power supply relay, Fuse panel B, Fuse panel C...........................................................................................................................................................................................................................................................................................................................................................................................................................................6257
3. Right rear ABS wheel speed sensor, Right front ABS wheel speed sensor, Left rear ABS wheel speed sensor, Left front ABS wheel speed sensor, Vacuum sensor, ABS control module............................................................................................................................................................................................................................................................................................................................................6258
4. ASR/ESP button, Tire pressure monitoring display button, ABS control module..............................................................................................................................................................................................................................................................................................................................................................................................................................................6259
5. Instrument cluster control module, Vehicle electrical control module system, Data bus on board diagnostic interface......................................................................................................................................................................................................................................................................................................................................................................................................6260
6. Brake fluid level warning switch, Left front brake pad wear sensor, Warning buzzer and tone, Instrument cluster control module, ABS indicator lamp, Brake system indicator lamp, ASR/ESP indicator lamp, Tire pressure monitoring display indicator lamp.................................................................................................................................................................................................................................................................6261
7. Steering angle sensor, Steering column electronics control module........................................................................................................................................................................................................................................................................................................................................................................................................................................................6262
009 -
Coolant fan..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6263
1.
Coolant fan.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6263
2. Battery, Motronic engine control module power supply relay, Coolant fan control module, Terminal 30 power supply relay, Fuse 1 (on fuse panel A), Fuse 3 (on fuse panel A), Fuse panel B.................................................................................................................................................................................................................................................................................................................................6264
3. Coolant fan control module, Coolant fan, Coolant fan 2...................................................................................................................................................................................................................................................................................................................................................................................................................................................................6265
010 -
Power socket 230V........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6266
1.
Power socket 230V.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6266
2. Inverter switch, Vehicle electrical system control module, Socket indicator lamp, Fuse 1 (on fuse panel A), Fuse panel B, Fuse panel C, Converter with socket, 12 V-230 V................................................................................................................................................................................................................................................................................................................................................6267
011 -
Seats, heated , (4A3)....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6268
1.
Seats, heated , (4A3)...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6268
2. Terminal 15 power supply relay, Vehicle electrical control module system, Fuse panel B, Fuse panel C.....................................................................................................................................................................................................................................................................................................................................................................................................................6269
3. Heated driver seat temperature sensor, Vehicle electrical control module system, Front seat heating control module, Driver seat heating element, Driver backrest heating element.........................................................................................................................................................................................................................................................................................................................................6270
4. Heated driver seat adjuster, Heated front passenger seat adjuster, Front passenger heated seat temperature sensor, Front passenger seat heating element, Front passenger backrest heating element........................................................................................................................................................................................................................................................................................................................6271
012 -
Lumbar support adjustment, without power seat adjustment.................................................................................................................................................................................................................................................................................................................................................................................................................................................................6272
1.
Lumbar support adjustment, without power seat adjustment................................................................................................................................................................................................................................................................................................................................................................................................................................................................6272
2. Driver seat lumbar support adjustment switch, Fuse panel B, Fuse panel C, Driver seat lumbar support height adjustment motor.............................................................................................................................................................................................................................................................................................................................................................................................6273
3. Front passenger seat lumbar support adjustment switch, Front passenger seat lumbar support curvature adjustment motor, Front passenger seat lumbar support height adjustment motor.......................................................................................................................................................................................................................................................................................................................................6274
013 -
Seat lumbar adjustment with power seats..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6275
1.
Seat lumbar adjustment with power seats.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6275
2. Seat forward/back adjustment button, Angle adjustment button, Seat height adjustment button, Backrest adjustment button, Fuse panel B, Driver power seat adjustment circuit breaker 1, Fuse panel C, Driver seat forward/back adjustment motor, Driver backrest adjustment motor, Driver seat height adjustment motor, Seat angle adjustment motor.......................................................................................................................................................................6276
3. Driver seat lumbar support adjustment switch, Front passenger seat lumbar support adjustment switch, Front passenger seat lumbar support curvature adjustment motor, Driver seat lumbar support height adjustment motor, Front passenger seat lumbar support height adjustment motor.....................................................................................................................................................................................................................................6277
014 -
Parking distance control without parallel parking assistance (park assist) , (7X1),(7X2).................................................................................................................................................................................................................................................................................................................................................................................................................................6278
1.
Parking distance control without parallel parking assistance (park assist) , (7X1),(7X2)................................................................................................................................................................................................................................................................................................................................................................................................................................6278
2. Terminal 15 power supply relay, Fuse 4 (on fuse panel C), Fuse 7 (on fuse panel B).......................................................................................................................................................................................................................................................................................................................................................................................................................................6279
3. Left rear parking aid sensor, Left rear center parking aid sensor, Right rear center parking aid sensor, Right rear parking aid sensor, Rear parking aid warning buzzer, Parking aid control module......................................................................................................................................................................................................................................................................................................................6280
4. Parking aid button, Front parking aid warning buzzer, Parking aid control module, Data bus on board diagnostic interface.................................................................................................................................................................................................................................................................................................................................................................................................6281
5. Right front parking aid sensor, Right front center parking aid sensor, Left front center parking aid sensor, Left front parking aid sensor, Parking aid control module...................................................................................................................................................................................................................................................................................................................................................6282
016 -
Cell phone system........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6283
1.
Cell phone system.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6283
2. Terminal 15 power supply relay, Voltage stabilizer, Fuse panel B, Fuse 2 (on fuse panel C), Fuse 48 (on fuse panel C)....................................................................................................................................................................................................................................................................................................................................................................................................6284
3. Cell phone operating electronics control module, Radio/navigation display unit control module, Voltage stabilizer, Data bus on board diagnostic interface, Radio.........................................................................................................................................................................................................................................................................................................................................................6285
4. Cell phone operating electronics control module, Radio/navigation display unit control module, Radio, Telephone microphone...............................................................................................................................................................................................................................................................................................................................................................................................6286
5. Telematics button module, Cell phone operating electronics control module................................................................................................................................................................................................................................................................................................................................................................................................................................................6287
6. Cell phone operating electronics control module, Roof antenna, Telephone antenna, Telephone baseplate, Auxiliary engine coolant heater radio frequency receiver, Auxiliary heater antenna................................................................................................................................................................................................................................................................................................................................6288
017 -
Washer system, headlamps , (8X1).........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6289
1.
Washer system, headlamps , (8X1)........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6289
2. Headlamp washer relay, Steering column electronics control module, Data bus on board diagnostic interface, Fuse 1 (on fuse panel A), Fuse 29 (on fuse panel B), Fuse 36 (on fuse panel C), Headlamp washer pump..........................................................................................................................................................................................................................................................................................................6290
3. Windshield wiper intermittent mode switch, Rear window wiper switch, Windshield and headlamp washer pump switch, Windshield washer fluid level sensor, Instrument cluster control module, Steering column electronics control module, Windshield washer fluid level indicator lamp.......................................................................................................................................................................................................................................6291
018 -
Climatic , (KH6),(9AP)...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6292
1.
Climatic , (KH6),(9AP)..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6292
2. Terminal 15 power supply relay, Fuse panel B, Fuse panel C...............................................................................................................................................................................................................................................................................................................................................................................................................................................................6293
3. Load reduction relay, A/C control module, A/C compressor regulator valve, Fuse panel C...................................................................................................................................................................................................................................................................................................................................................................................................................................6294
4. High pressure sensor, Center vent temperature sensor, A/C control module, Recirculation door motor.......................................................................................................................................................................................................................................................................................................................................................................................................................6295
5. Footwell vent temperature sensor, Evaporator vent temperature sensor, A/C control module, Temperature control door motor, Air distribution door motor....................................................................................................................................................................................................................................................................................................................................................................6296
6. Fresh air blower switch, A/C control module, Fresh air blower series resistor with fuse, Fresh air blower................................................................................................................................................................................................................................................................................................................................................................................................................6297
7. A/C control module, Data bus on board diagnostic interface...............................................................................................................................................................................................................................................................................................................................................................................................................................................................6298
019 -
Auxiliary air heater (PTC) , (7E6).......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6299
1.
Auxiliary air heater (PTC) , (7E6)......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6299
2. Low heat output relay, High heat output relay, Fuse 1 (on fuse panel A), Fuse 4 (on fuse panel A), Fuse 6 (on fuse panel A), Auxiliary heater heating element............................................................................................................................................................................................................................................................................................................................................................6300
3. Terminal 30 power supply relay, Engine control module, Fuse panel B......................................................................................................................................................................................................................................................................................................................................................................................................................................................6301
4. Fresh air blower switch, A/C control module, Fresh air blower series resistor with fuse, Fresh air blower................................................................................................................................................................................................................................................................................................................................................................................................................6302
020 -
Climatronic , (9AK)......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6303
1.
Climatronic , (9AK).....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6303
2. Terminal 15 power supply relay, Fuse 1 (on fuse panel A), Fuse 4 (on fuse panel C), Fuse 5 (on fuse panel A), Fuse 7 (on fuse panel B), Fuse 14 (on fuse panel C), Fuse 22 (on fuse panel C).............................................................................................................................................................................................................................................................................................................................6304
3. High pressure sensor, Air quality sensor, Climatronic control module.....................................................................................................................................................................................................................................................................................................................................................................................................................................................6305
4. Climatronic control module, Left temperature control door motor, Right temperature control door motor....................................................................................................................................................................................................................................................................................................................................................................................................................6306
5. Climatronic control module, Defroster door motor, Fresh air/recirculating air/back pressure door motor, Front air distribution door motor................................................................................................................................................................................................................................................................................................................................................................................6307
6. Sunlight photo sensor, Sunlight photo sensor 2, Left vent temperature sensor, Right vent temperature sensor, Climatronic control module..................................................................................................................................................................................................................................................................................................................................................................................6308
7. Fresh air blower control module, Climatronic control module, Data bus on board diagnostic interface, Fresh air blower....................................................................................................................................................................................................................................................................................................................................................................................................6309
022 -
Dynamic Chassis Control (DCC) , (2H1)....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6310
1.
Dynamic Chassis Control (DCC) , (2H1)...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6310
2. Electronic damping control module, Terminal 15 power supply relay, Fuse 7 (on fuse panel B), Fuse 29 (on fuse panel B)...................................................................................................................................................................................................................................................................................................................................................................................................6311
3. Damping adjustment button, Left front body acceleration sensor, Electronic damping control module, Left front damping adjustment valve, Right front damping adjustment valve.............................................................................................................................................................................................................................................................................................................................................6312
4. Left front level control system sensor, Right front level control system sensor, Right front body acceleration sensor, Rear body acceleration sensor, Electronic damping control module, Left rear damping adjustment valve..............................................................................................................................................................................................................................................................................................6313
5. Left rear level control system sensor, Multifunction indicator, Electronic damping control module, Instrument cluster control module, Right rear damping adjustment valve................................................................................................................................................................................................................................................................................................................................................6314
023 -
Power steering, electromechanical , (1N3),(QZ0)..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6315
1.
Power steering, electromechanical , (1N3),(QZ0).........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6315
2. Terminal 15 power supply relay, Fuse 2 (on fuse panel A), Fuse panel B, Fuse 7 (on fuse panel B), Fuse panel C, Fuse 2 (on fuse panel C).................................................................................................................................................................................................................................................................................................................................................................................6316
3. Steering angle sensor, Steering torque sensor, Power steering control module, Electromechanical power steering motor.....................................................................................................................................................................................................................................................................................................................................................................................................6317
4. Instrument cluster control module, Data bus on board diagnostic interface, Electromechanical power steering indicator lamp...............................................................................................................................................................................................................................................................................................................................................................................................6318
024 -
Steering wheel, multifunction............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6319
1.
Steering wheel, multifunction...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6319
2. Battery, Battery monitoring control module, Voltage stabilizer...........................................................................................................................................................................................................................................................................................................................................................................................................................................................6320
3. Terminal 15 power supply relay, Fuse panel B, Fuse panel C...............................................................................................................................................................................................................................................................................................................................................................................................................................................................6321
4. Multifunction indicator, Instrument cluster control module, Data bus on board diagnostic interface.......................................................................................................................................................................................................................................................................................................................................................................................................................6322
5. Ignition/starter switch, Steering column electronics control module, Ignition switch key lock solenoid...................................................................................................................................................................................................................................................................................................................................................................................................................6323
6. Signal horn activation, Multifunction steering wheel control module, Steering column electronics control module, Driver airbag igniter...................................................................................................................................................................................................................................................................................................................................................................................6324
7. Turn signal switch, Headlamp dimmer/flasher switch, Cruise control switch, Cruise control -SET- button, Left multifunction buttons on steering wheel, Right multifunction buttons on steering wheel, tiptronic upshift button, tiptronic downshift button, Multifunction steering wheel control module, Steering column electronics control module.......................................................................................................................................................................6325
025 -
Radio system , (7Q0).....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6326
1.
Radio system , (7Q0)....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6326
2. Rear window defogger relay, Terminal 15 power supply relay, Voltage stabilizer...........................................................................................................................................................................................................................................................................................................................................................................................................................................6327
3. Voltage stabilizer, Radio, External audio source connection..............................................................................................................................................................................................................................................................................................................................................................................................................................................................6328
4. Cell phone operating electronics control module, Radio, Left front treble speaker, Left front bass speaker, Right front treble speaker, Right front bass speaker.........................................................................................................................................................................................................................................................................................................................................................6329
5. Radio, Left rear treble speaker, Left rear bass speaker, Right rear treble speaker, Right rear bass speaker, CD changer..................................................................................................................................................................................................................................................................................................................................................................................................6330
6. Radio, Left antenna module, Right antenna module, AM frequency filter, FM frequency filter in negative wire, FM frequency filter in positive wire, Rear window defogger..................................................................................................................................................................................................................................................................................................................................................6331
026 -
Radio system with digital sound package , (9VE)..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6332
1.
Radio system with digital sound package , (9VE).........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6332
2. Rear window defogger relay, Terminal 15 power supply relay...............................................................................................................................................................................................................................................................................................................................................................................................................................................................6333
3. Voltage stabilizer, Antenna, Left antenna module, AM frequency filter, FM frequency filter in negative wire, Rear window defogger........................................................................................................................................................................................................................................................................................................................................................................................6334
4. Radio, Radio antenna 2, Right antenna module, AM frequency filter, FM frequency filter in positive wire, Digital radio antenna, External audio source connection, Rear window defogger...................................................................................................................................................................................................................................................................................................................................6335
5. Cell phone operating electronics control module, Radio, CD changer.......................................................................................................................................................................................................................................................................................................................................................................................................................................................6336
6. Radio, Amplifier, Left front treble speaker, Left front bass speaker, Right front treble speaker, Right front bass speaker...............................................................................................................................................................................................................................................................................................................................................................................................6337
7. Amplifier, Left rear treble speaker, Left rear bass speaker..............................................................................................................................................................................................................................................................................................................................................................................................................................................................6338
8. Amplifier, Right rear treble speaker, Right rear bass speaker............................................................................................................................................................................................................................................................................................................................................................................................................................................................6339
027 -
Radio navigation system RNS 310..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6340
1.
Radio navigation system RNS 310.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6340
2. Rear window defogger relay, Terminal 15 power supply relay, Voltage stabilizer...........................................................................................................................................................................................................................................................................................................................................................................................................................................6341
3. Radio/navigation display unit control module, Voltage stabilizer, External audio source connection.......................................................................................................................................................................................................................................................................................................................................................................................................................6342
4. Cell phone operating electronics control module, Radio/navigation display unit control module, Left front treble speaker, Left front bass speaker, Right front treble speaker, Right front bass speaker..................................................................................................................................................................................................................................................................................................................6343
5. Radio/navigation display unit control module, Left rear treble speaker, Left rear bass speaker, Right rear treble speaker, Right rear bass speaker, CD changer...........................................................................................................................................................................................................................................................................................................................................................6344
6. Radio/navigation display unit control module, GPS antenna, Telephone antenna, Left antenna module, AM frequency filter, FM frequency filter in negative wire, Auxiliary heater antenna, Rear window defogger.............................................................................................................................................................................................................................................................................................................6345
7. Right antenna module, AM frequency filter, FM frequency filter in positive wire, Rear window defogger....................................................................................................................................................................................................................................................................................................................................................................................................................6346
028 -
Radio navigation system with digital sound package.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6347
1.
Radio navigation system with digital sound package......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6347
2. Rear window defogger relay, Terminal 15 power supply relay, Voltage stabilizer...........................................................................................................................................................................................................................................................................................................................................................................................................................................6348
3. Voltage stabilizer, Antenna, AM frequency filter, FM frequency filter in negative wire, Rear window defogger.............................................................................................................................................................................................................................................................................................................................................................................................................6349
4. Radio/navigation display unit control module, Radio antenna 2, Left antenna module, Right antenna module, AM frequency filter, FM frequency filter in positive wire, Digital radio antenna, External audio source connection, Rear window defogger.......................................................................................................................................................................................................................................................................6350
5. Radio/navigation display unit control module, GPS antenna, Telephone antenna, Auxiliary heater antenna...................................................................................................................................................................................................................................................................................................................................................................................................................6351
6. Cell phone operating electronics control module, Radio/navigation display unit control module, CD changer................................................................................................................................................................................................................................................................................................................................................................................................................6352
7. Amplifier, Left front treble speaker, Left front bass speaker, Right front treble speaker, Right front bass speaker......................................................................................................................................................................................................................................................................................................................................................................................................6353
8. Amplifier, Left rear treble speaker, Left rear bass speaker..............................................................................................................................................................................................................................................................................................................................................................................................................................................................6354
9. Amplifier, Right rear treble speaker, Right rear bass speaker............................................................................................................................................................................................................................................................................................................................................................................................................................................................6355
029 -
MEDIA-IN multimedia socket...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6356
1.
MEDIA-IN multimedia socket..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6356
2. Radio/navigation display unit control module, Radio, External audio source connection, External multimedia device interface..............................................................................................................................................................................................................................................................................................................................................................................................6357
032 -
Automatic transmission - DSG 02E , (G1A).................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6358
1.
Automatic transmission - DSG 02E , (G1A)................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6358
2. Fuse 1 (on fuse panel A), Fuse 2 (on fuse panel C), Fuse 5 (on fuse panel A), Fuse 14 (on fuse panel C)..................................................................................................................................................................................................................................................................................................................................................................................................................6359
3. Transmission input speed sensor, Clutch oil temperature sensor, Terminal 15 power supply relay, DSG transmission Mechatronic, Solenoid valve 1, Solenoid valve 2, Fuse panel B...........................................................................................................................................................................................................................................................................................................................................6360
4. Selector lever, Selector lever park position lock switch, DSG transmission Mechatronic, Solenoid valve 4, Solenoid valve 5, Shift lock solenoid, Automatic transmission pressure regulating valve 1, Automatic transmission pressure regulating valve 2..................................................................................................................................................................................................................................................................6361
5. Selector lever, Automatic transmission hydraulic pressure sensor 1, Automatic transmission hydraulic pressure sensor 2, Gear position distance sensor 1, Gear position distance sensor 2, Gear position distance sensor 3, DSG transmission Mechatronic, Automatic transmission pressure regulating valve 3, Automatic transmission pressure regulating valve 4, Automatic transmission pressure regulating valve 5, Automatic transmission pressure regulating valve 6, Transmission range display......................6362
6. Transmission fluid temperature sensor, Transmission output speed sensor, Transmission output speed sensor 2, Gear position distance sensor 4, Driveshaft speed sensor 1, Driveshaft speed sensor 2, Temperature sensor in control module, DSG transmission Mechatronic...................................................................................................................................................................................................................................................6363
7. Multifunction indicator, Instrument cluster control module, Data bus on board diagnostic interface.......................................................................................................................................................................................................................................................................................................................................................................................................................6364
038 -
Rearview camera (Rear Assist) , (7X9),(8A0)..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6365
1.
Rearview camera (Rear Assist) , (7X9),(8A0).............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6365
2. Release button in rear lid handle, Radio/navigation display unit control module, Vehicle electrical control module system, Rearview camera, Fuse 5 (on fuse panel A), Fuse 16 (on fuse panel C), Emblem motor............................................................................................................................................................................................................................................................................................................6366
3. Radio/navigation display unit control module, Navigation system control module, Rearview camera..........................................................................................................................................................................................................................................................................................................................................................................................................................6367
039 -
Engine preheating , (7VP)................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6368
1.
Engine preheating , (7VP)...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6368
2. Exterior socket, 230 V, 110 V, Engine preheating element.................................................................................................................................................................................................................................................................................................................................................................................................................................................................6369
040 -
Network data bus.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6370
1.
Network data bus........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6370
2. Battery, Terminal 15 power supply relay, Battery monitoring control module, Fuse 5 (on fuse panel A).....................................................................................................................................................................................................................................................................................................................................................................................................................6371
3. Fuse panel B, Fuse panel C...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6372
4. Interior monitoring sensor, Rain/light recognition sensor, Alarm horn, Wiper motor control module, Driver windshield wiper motor.........................................................................................................................................................................................................................................................................................................................................................................................6373
5. Multifunction indicator, Instrument cluster control module, Data bus on board diagnostic interface.......................................................................................................................................................................................................................................................................................................................................................................................................................6374
6. Compass magnetic field sensor, Climatronic control module, Towing recognition control module, Auxiliary heater control module, Cell phone operating electronics control module, Radio/navigation display unit control module, Radio, Amplifier, TV tuner, Ex ernal multimedia device interface...........................................................................................................................................................................................................................6375
7. A/C control module, Driver door control module, Front passenger door control module, Left rear door control module, Right rear door control module, Multifunction steering wheel control module, Access/start authorization control module, Steering column electronics control module...................................................................................................................................................................................................................................6376
8. Selector lever, Transmission control module, Airbag control module, Electronic damping control module, Parking aid control module, Multifunction steering wheel control module, Steering column electronics control module, Selector lever sensor system con rol module, DSG transmission Mechatronic, Parallel parking assistance control module, Driver assistance systems front camera, Automatic dimming interior rearview mirror....................................................................................6377
9. ABS control module, Power steering control module, Engine control module, Left headlamp power output module, Right headlamp power output module, Cornering lamp and headlamp range control module, Structure borne sound control module..................................................................................................................................................................................................................................................................................6378
046 -
2.5L gasoline engine , CBTA, CBUA........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6379
1.
2.5L gasoline engine , CBTA, CBUA.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6379
2. Battery, Starter, Generator, Fuse 1 (on fuse panel A), Fuse 2 (on fuse panel C), Fuse 5 (on fuse panel A), Fuse 27 (on fuse panel C).....................................................................................................................................................................................................................................................................................................................................................................................6380
3. Fuel pump relay, Terminal 15 power supply relay, Fuel primer relay, Terminal 50 power supply relay, Fuse panel B.........................................................................................................................................................................................................................................................................................................................................................................................................6381
4. Secondary air injection pump relay, Fuse panel B, Secondary air injection pump motor.....................................................................................................................................................................................................................................................................................................................................................................................................................................6382
5. Motronic engine control module power supply relay, Engine control module, Fuse panel B...................................................................................................................................................................................................................................................................................................................................................................................................................................6383
6. Engine control module, Ignition coil 1 with power output stage, Ignition coil 2 with power output stage, Ignition coil 3 with power output stage, Ignition coil 4 with power output stage, Spark plugs...................................................................................................................................................................................................................................................................................................................6384
7. Engine coolant temperature sensor, Engine coolant temperature sensor on radiator outlet, Throttle valve control module, Engine control module, Ignition coil 5 with power output stage...................................................................................................................................................................................................................................................................................................................................6385
8. Camshaft position sensor, Intake air temperature sensor, Knock sensor 1, Knock sensor 2, Manifold absolute pressure sensor, Secondary air injection sensor 1, Engine control module......................................................................................................................................................................................................................................................................................................................................6386
9. Engine speed sensor, Camshaft position sensor, Engine control module, Cylinder 1 fuel injector, Cylinder 2 fuel injector, Cylinder 3 fuel injector, Cylinder 4 fuel injector, Cylinder 5 fuel injector, Leak detection pump..............................................................................................................................................................................................................................................................................................6387
10. Accelerator pedal position sensor, Accelerator pedal position sensor 2, Engine control module, EVAP canister purge regulator valve 1, Secondary air injection solenoid valve, Camshaft adjustment valve 1...............................................................................................................................................................................................................................................................................................................6388
11. Heated oxygen sensor, Oxygen sensor after catalytic converter, Center oxygen sensor for bank 1 catalytic converter, Engine control module...............................................................................................................................................................................................................................................................................................................................................................................6389
12. Brake lamp switch, Center oxygen sensor for bank 1 catalytic converter, Clutch position sensor, Engine control module...................................................................................................................................................................................................................................................................................................................................................................................................6390
13. Vehicle electrical control module system, Engine control module.........................................................................................................................................................................................................................................................................................................................................................................................................................................................6391
14. Multifunction indicator, Instrument cluster control module, Vehicle electrical control module system, Data bus on board diagnostic interface............................................................................................................................................................................................................................................................................................................................................................................6392
15. Oil pressure switch, Fuel level sensor, Fuel gauge, Engine coolant temperature gauge, Transfer fuel pump, Engine coolant level sensor, Instrument cluster control module................................................................................................................................................................................................................................................................................................................................................6393
047 -
Automatic transmission 6-speed , (0ER)...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6394
1.
Automatic transmission 6-speed , (0ER)..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6394
2. Terminal 15 power supply relay, Fuse 1 (on fuse panel A), Fuse 2 (on fuse panel C), Fuse 5 (on fuse panel A), Fuse 7 (on fuse panel B), Fuse 14 (on fuse panel C), Fuse 30 (on fuse panel C).............................................................................................................................................................................................................................................................................................................................6395
3. Transmission control module..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6396
4. Transmission control module, Solenoid valve 1, Solenoid valve 2, Solenoid valve 3, Solenoid valve 4, Solenoid valve 5, Solenoid valve 6, Solenoid valve 9, Solenoid valve 10.............................................................................................................................................................................................................................................................................................................................................6397
5. tiptronic switch, Selector lever park position lock switch, Transmission control module, Shift lock solenoid, Transmission range display.................................................................................................................................................................................................................................................................................................................................................................................6398
6. tiptronic switch, Transmission fluid temperature sensor, Transmission input speed sensor, Transmission control module, Transmission range display........................................................................................................................................................................................................................................................................................................................................................................6399
7. Transmission output speed sensor, Transmission control module, Data bus on board diagnostic interface....................................................................................................................................................................................................................................................................................................................................................................................................................6400
8. Multifunction indicator, Instrument cluster control module...............................................................................................................................................................................................................................................................................................................................................................................................................................................................6401
048 -
All wheel drive (4MOTION) , (1X1)........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6402
1.
All wheel drive (4MOTION) , (1X1).......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6402
2. Terminal 15 power supply relay, All wheel drive control module, Fuse panel B, Fuse panel C, Haldex clutch pump...........................................................................................................................................................................................................................................................................................................................................................................................................6403
3. Fuel level sensor 2, Oil pressure/temperature sensor, Instrument cluster control module, All wheel drive control module, Data bus on board diagnostic interface, Haldex clutch control valve.............................................................................................................................................................................................................................................................................................................................6405
051 -
Adaptive cruise control..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6406
1.
Adaptive cruise control.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6406
2. Terminal 15 power supply relay, Fuse 1 (on fuse panel C), Fuse 7 (on fuse panel B).......................................................................................................................................................................................................................................................................................................................................................................................................................................6407
3. Adaptive cruise control sensor, Distance regulation control module, Vehicle electrical system control module, Data bus on board diagnostic interface.....................................................................................................................................................................................................................................................................................................................................................................6408
4. Turn signal switch, Headlamp dimmer/flasher switch, Cruise control switch, Cruise control -SET- button, Adaptive cruise control button, Steering column electronics control module.......................................................................................................................................................................................................................................................................................................................................6409
052 -
Standard equipment (NAR).................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6410
1.
Standard equipment (NAR)................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6410
2. Battery, Terminal 15 power supply relay, Fuse 1 (on fuse panel A), Fuse 5 (on fuse panel A), Fuse panel B................................................................................................................................................................................................................................................................................................................................................................................................................6411
3. Fuse panel B, Fuse panel C...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6412
4. Fuse panel C.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6413
5. Load reduction relay, Fuse panel C.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6414
6. Ignition/starter switch, Steering column electronics control module, Ignition switch key lock solenoid...................................................................................................................................................................................................................................................................................................................................................................................................................6415
7. Signal horn activation, Steering column electronics control module, Driver airbag igniter................................................................................................................................................................................................................................................................................................................................................................................................................................6416
8. Turn signal switch, Headlamp dimmer/flasher switch, Windshield wiper intermittent mode switch, Rear window wiper switch, Windshield wiper intermittent regulator, Windshield and headlamp washer pump switch, Cruise control switch, Multifunction indicator selection switch, Multifunction indicator memory switch, Cruise control -SET- button, Steering column electronics control module............................................................................................................................6417
9. Left front fog lamp bulb, Left cornering lamp bulb, Left daytime running lamp bulb, Left position lamp bulb, Left front turn signal bulb, Left low beam headlamp bulb, Left high beam headlamp bulb, Left front side marker lamp bulb....................................................................................................................................................................................................................................................................................6418
10. Instrument panel and switch illumination dimmer switch, Back-up lamp switch, Engine hood contact switch, High tone horn, Low tone horn, Dual tone horn relay............................................................................................................................................................................................................................................................................................................................................................6419
11. Right front fog lamp bulb, Right cornering lamp bulb, Right position lamp bulb, Right front turn signal bulb, Right low beam headlamp bulb, Right high beam headlamp bulb, Right front side marker lamp bulb............................................................................................................................................................................................................................................................................................................6420
12. Light switch, Fog lamp switch, Fog lamp indicator lamp, Automatic light control indicator lamp..........................................................................................................................................................................................................................................................................................................................................................................................................................6421
13. Right tail lamp bulb, Left tail lamp bulb, Left rear turn signal bulb, Right rear turn signal bulb, Left back-up lamp bulb, Right back-up lamp bulb, Left brake/tail lamp bulb, Right brake/tail lamp bulb..............................................................................................................................................................................................................................................................................................................6422
14. Rear window defogger relay, Driver exterior rearview mirror turn signal bulb, Front passenger exterior rearview mirror turn signal bulb, High-mounted brake lamp bulb, Left license plate lamp, Right license plate lamp, Rear window defogger..........................................................................................................................................................................................................................................................................6423
15. Emergency flasher button, Left washer nozzle heater, Right washer nozzle heater.........................................................................................................................................................................................................................................................................................................................................................................................................................................6424
16. Rain/light recognition sensor, Wiper motor control module, Rear window wiper motor, Windshield and rear window washer pump, Driver windshield wiper motor...............................................................................................................................................................................................................................................................................................................................................................6425
17. Glove compartment lamp switch, Brake lamp switch, Luggage compartment lamp, Glove compartment lamp......................................................................................................................................................................................................................................................................................................................................................................................................................6426
18. Front interior lamp, Left rear reading lamp, Right rear reading lamp, Front passenger reading lamp, Driver reading lamp, Rear interior lamp.............................................................................................................................................................................................................................................................................................................................................................................6427
19. Driver vanity mirror lamp contact switch, Front passenger vanity mirror lamp contact switch, Blocking diode, Cigarette lighter illumination bulb, Cigarette lighter, 12 V socket, Left footwell lamp, Right footwell lamp, Front passenger vanity mirror lamp, Driver vanity mirror lamp................................................................................................................................................................................................................................6428
20. Fresh air blower switch, Heater/heat output switch, Fresh air blower series resistor with fuse, Fresh air blower, Recirculation door motor..............................................................................................................................................................................................................................................................................................................................................................................6429
21. Data bus on board diagnostic interface, Diagnostic connection...........................................................................................................................................................................................................................................................................................................................................................................................................................................................6430
22. Anti-theft immobilizer reader coil, Brake fluid level warning switch, Warning buzzer and tone, Instrument cluster control module, Cruise control indicator lamp, Anti-theft immobilizer indicator lamp, Door ajar indicator lamp, Lamp failure indicator lamp, Hood -open- indicator lamp...............................................................................................................................................................................................................................6431
23. Parking brake indicator lamp switch, Tachometer, Speedometer, Windshield washer fluid level sensor, Left front brake pad wear sensor, Instrument cluster control module, High beam indicator lamp, Windshield washer fluid level indicator lamp.........................................................................................................................................................................................................................................................................6432
24. Fuel gauge, Engine coolant temperature gauge, Outside air temperature sensor, Engine coolant level sensor, Multifunction indicator, Instrument cluster control module, Position lamp indicator lamp, Rear fog lamp indicator lamp, Engine electronics indicator lamp, Odometer display..................................................................................................................................................................................................................................6433
053 -
Comfort system (NAR) , (0A1).............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6434
1.
Comfort system (NAR) , (0A1)............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6434
2. Terminal 15 power supply relay, Fuse 5 (on fuse panel A), Fuse panel B, Fuse panel C.....................................................................................................................................................................................................................................................................................................................................................................................................................................6435
3. Left front window regulator switch, Right front power window switch in driver door, Driver interior locking button, Driver door control module, Central locking -SAFE- indicator lamp, Driver window regulator motor.....................................................................................................................................................................................................................................................................................................6436
4. Mirror adjusting switch, Mirror selector switch, Exterior rearview mirror heating switch, Mirror folding switch, Driver door contact switch, Driver central locking lock unit, Driver door control module, Driver door central locking system motor......................................................................................................................................................................................................................................................................6437
5. Exterior rearview mirror horizontal adjustment position sensor, Exterior rearview mirror vertical adjustment position sensor, Driver door control module, Driver exterior rearview mirror turn signal bulb, Driver mirror adjustment motor 2, Driver exterio
rearview mirror folding motor, Heated driver exterior rearview mirror......................................................................................................................................................................................6438
6. Driver door control module, Front passenger exterior rearview mirror turn signal bulb, Driver entry lamp in exterior rearview mirror, Driver automatic dimming exterior rearview mirror, Heated front passenger exterior rearview mirror.................................................................................................................................................................................................................................................................................6439
7. Exterior rearview mirror horizontal adjustment position sensor, Exterior rearview mirror vertical adjustment position sensor, Front passenger side mirror adjustment motor 2, Front passenger exterior rearview mirror folding motor, Front passenger entry lamp in exterior rearview mirror.............................................................................................................................................................................................................................6440
8. Front passenger door window regulator switch, Front passenger door contact switch, Front passenger central locking lock unit, Front passenger door central locking system motor, Front passenger window regulator motor..................................................................................................................................................................................................................................................................................................6441
9. Release button in rear lid handle, Luggage compartment lamp switch, Rear lid unlock motor, Luggage compartment lamp......................................................................................................................................................................................................................................................................................................................................................................................................6442
10. Sunroof adjustment regulator, Sunroof button, Alarm horn, Power sunroof control module, Sunroof motor, Front interior lamp..............................................................................................................................................................................................................................................................................................................................................................................................6443
11. Automatic dimming interior rearview mirror switch, Central locking and anti-theft alarm system antenna, Fuel filler door unlock motor, Automatic dimming interior rearview mirror.......................................................................................................................................................................................................................................................................................................................................6444
12. Engine hood contact switch..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6445
054 -
Comfort system (NAR) , (0A2).............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6446
1.
Comfort system (NAR) , (0A2)............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6446
2. Fuse 5 (on fuse panel A), Fuse panel C...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6447
3. Terminal 15 power supply relay, Driver door control module, Fuse panel B, Fuse panel C, Driver window regulator motor....................................................................................................................................................................................................................................................................................................................................................................................................6448
4. Left front window regulator switch, Left rear window regulator switch in driver door, Right rear window regulator switch in driver door, Right front power window switch in driver door, Child safety lock button, Driver door control module............................................................................................................................................................................................................................................................................6449
5. Left front window regulator switch, Right front power window switch in driver door, Driver interior locking button, Driver door control module, Central locking -SAFE- indicator lamp....................................................................................................................................................................................................................................................................................................................................6450
6. Mirror adjusting switch, Mirror selector switch, Exterior rearview mirror heating switch, Mirror folding switch, Driver door contact switch, Driver central locking lock unit, Driver door control module, Driver door central locking system motor......................................................................................................................................................................................................................................................................6451
7. Exterior rearview mirror horizontal adjustment position sensor, Exterior rearview mirror vertical adjustment position sensor, Driver door control module, Driver exterior rearview mirror turn signal bulb, Driver mirror adjustment motor 2, Driver exterio
rearview mirror folding motor, Heated driver exterior rearview mirror......................................................................................................................................................................................6452
8. Driver door control module, Front passenger exterior rearview mirror turn signal bulb, Driver entry lamp in exterior rearview mirror, Driver automatic dimming exterior rearview mirror, Heated front passenger exterior rearview mirror.................................................................................................................................................................................................................................................................................6453
9. Exterior rearview mirror horizontal adjustment position sensor, Exterior rearview mirror vertical adjustment position sensor, Front passenger side mirror adjustment motor 2, Front passenger exterior rearview mirror folding motor, Front passenger entry lamp in exterior rearview mirror.............................................................................................................................................................................................................................6454
10. Front passenger door window regulator switch, Front passenger door contact switch, Front passenger central locking lock unit, Front passenger door central locking system motor, Front passenger window regulator motor.................................................................................................................................................................................................................................................................................................6455
11. Left rear power window switch in left rear door, Left rear door contact switch, Left rear central locking lock unit, Left rear door control module, Left rear window regulator motor, Left rear central locking -lock- motor............................................................................................................................................................................................................................................................................................6456
12. Right rear window switch in right rear door, Right rear door contact switch, Right rear central locking lock unit, Right rear door control module, Right rear window regulator motor, Right rear central locking -lock- motor...........................................................................................................................................................................................................................................................................................6457
13. Left rear door contact switch, Right rear door contact switch, Left rear central locking lock unit, Right rear central locking lock unit, Left rear central locking -lock- motor, Right rear central locking -lock- motor...............................................................................................................................................................................................................................................................................................6458
14. Release button in rear lid handle, Luggage compartment lamp switch, Rear lid unlock motor, Fuel filler door unlock motor, Luggage compartment lamp......................................................................................................................................................................................................................................................................................................................................................................6459
15. Sunroof adjustment regulator, Sunroof button, Alarm horn, Power sunroof control module, Sunroof motor...................................................................................................................................................................................................................................................................................................................................................................................................................6460
16. Automatic dimming interior rearview mirror switch, Engine hood contact switch, Central locking and anti-theft alarm system antenna, Automatic dimming interior rearview mirror..........................................................................................................................................................................................................................................................................................................................................6461
055 -
Airbag systems (USA) , (4UM),(4UT).......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6462
1.
Airbag systems (USA) , (4UM),(4UT)......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6462
2. Airbag control module, Terminal 15 power supply relay, Front passenger airbag -disabled- indicator lamp, Fuse 3 (on fuse panel C), Fuse 4 (on fuse panel C), Fuse 7 (on fuse panel B)....................................................................................................................................................................................................................................................................................................................................6463
3. Driver front airbag crash sensor, Passenger side front airbag crash sensor, Airbag control module, Steering column electronics control module, Driver airbag igniter, Front passenger airbag igniter 1, Front passenger airbag igniter 2.................................................................................................................................................................................................................................................................................6464
4. Driver thorax airbag crash sensor, Front passenger thorax airbag crash sensor, Driver side rear thorax airbag crash sensor, Airbag control module, Driver thorax airbag igniter, Front passenger thorax airbag igniter, Driver head curtain airbag igniter...............................................................................................................................................................................................................................................................6465
5. Passenger side rear thorax airbag crash sensor, Driver belt force limiter, Airbag control module, Driver seat belt tensioner igniter 1, Front passenger seat belt tensioner igniter 1, Driver side rear seat belt tensioner igniter, Front passenger head cu
tain airbag igniter.........................................................................................................................................................................................................................................6466
6. Driver seat belt switch, Front passenger seat belt switch, Passenger occupant detection system seat belt force sensor, Driver seat position sensor, Airbag control module, Passenger side rear seat belt tensioner igniter, Driver side rear thorax airbag igniter, Passenger side rear thorax airbag igniter............................................................................................................................................................................................................6467
7. Passenger occupant detection system pressure sensor, Warning buzzer and tone, Airbag control module, Instrument cluster control module, Data bus on board diagnostic interface, Seat belt indicator lamp, Airbag indicator lamp..........................................................................................................................................................................................................................................................................................6468
056 -
Compass , (QR1)..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6469
1.
Compass , (QR1).........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6469
2. Terminal 15 power supply relay, Fuse panel B, Fuse 2 (on fuse panel C), Fuse 5 (on fuse panel A), Fuse 13 (on fuse panel C)..............................................................................................................................................................................................................................................................................................................................................................................................6470
3. Compass magnetic field sensor, Voltage stabilizer, Data bus on board diagnostic interface, Fuse 48 (on fuse panel C).....................................................................................................................................................................................................................................................................................................................................................................................................6471
057 -
2.0L gasoline engine , CBFA..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6472
1.
2.0L gasoline engine , CBFA.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6472
2. Battery, Starter, Generator, Vehicle electrical control module system, Terminal 50 power supply relay, Fuse 1 (on fuse panel A), Fuse 5 (on fuse panel A)................................................................................................................................................................................................................................................................................................................................................................6473
3. Fuel level sensor, Transfer fuel pump, Terminal 15 power supply relay, Vehicle electrical control module system, Secondary air injection pump motor......................................................................................................................................................................................................................................................................................................................................................................6474
4. Secondary air injection pump relay, Fuel pump control module.............................................................................................................................................................................................................................................................................................................................................................................................................................................................6475
5. Motronic engine control module power supply relay, Engine control module.................................................................................................................................................................................................................................................................................................................................................................................................................................................6476
6. Engine control module, Ignition coil 1 with power output stage, Ignition coil 2 with power output stage, Ignition coil 3 with power output stage, Ignition coil 4 with power output stage................................................................................................................................................................................................................................................................................................................................6477
7. Engine coolant temperature sensor, Coolant circulation pump relay, Throttle valve control module, Engine control module, After-run coolant pump..........................................................................................................................................................................................................................................................................................................................................................................6478
8. Camshaft position sensor, Knock sensor 1, Fuel pressure sensor, Engine control module, Fuel pressure regulator valve.....................................................................................................................................................................................................................................................................................................................................................................................................6479
9. Engine speed sensor, Charge air pressure sensor, Intake air temperature sensor, Intake manifold runner position sensor, Secondary air injection sensor 1, Engine control module..........................................................................................................................................................................................................................................................................................................................................6480
10. Mass airflow sensor, Engine coolant temperature sensor on radiator outlet, Engine control module, Cylinder 1 fuel injector, Cylinder 2 fuel injector, Cylinder 3 fuel injector, Cylinder 4 fuel injector................................................................................................................................................................................................................................................................................................................6481
11. Engine control module, Wastegate bypass regulator valve, EVAP canister purge regulator valve 1, Secondary air injection solenoid valve, Camshaft adjustment valve 1, Turbocharger recirculation valve, Intake manifold runner control valve.............................................................................................................................................................................................................................................................................6482
12. Heated oxygen sensor, Accelerator pedal position sensor, Accelerator pedal position sensor 2, Engine control module.....................................................................................................................................................................................................................................................................................................................................................................................................6483
13. Heated oxygen sensor 2, Oxygen sensor after catalytic converter, Radiator identification sensor, Engine control module, Leak detection pump.............................................................................................................................................................................................................................................................................................................................................................................6484
14. Brake lamp switch, Clutch position sensor, Engine control module........................................................................................................................................................................................................................................................................................................................................................................................................................................................6485
15. Data bus on board diagnostic interface, Malfunction indicator lamp......................................................................................................................................................................................................................................................................................................................................................................................................................................................6486
16. Oil pressure switch, Reduced oil pressure switch, Fuel gauge, Engine coolant temperature gauge, Engine coolant level sensor, Multifunction indicator....................................................................................................................................................................................................................................................................................................................................................................6487
058 -
2.0L gasoline engine , CCTA..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6488
1.
2.0L gasoline engine , CCTA.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6488
2. Battery, Starter, Generator, Terminal 50 power supply relay, Fuse 1 (on fuse panel A)....................................................................................................................................................................................................................................................................................................................................................................................................................................6489
3. Terminal 15 power supply relay, Fuse 5 (on fuse panel A), Fuse panel B...................................................................................................................................................................................................................................................................................................................................................................................................................................................6490
4. Fuel level sensor, Transfer fuel pump, Fuel pump control module, Engine component power supply relay, Fuse panel B.......................................................................................................................................................................................................................................................................................................................................................................................................6491
5. Motronic engine control module power supply relay, Fuse panel B..........................................................................................................................................................................................................................................................................................................................................................................................................................................................6492
6. Steering column electronics control module, Engine control module........................................................................................................................................................................................................................................................................................................................................................................................................................................................6493
7. Mass airflow sensor, Engine coolant temperature sensor on radiator outlet, Coolant circulation pump relay, Throttle valve control module, Engine control module, After-run coolant pump..................................................................................................................................................................................................................................................................................................................................6494
8. Engine control module, Ignition coil 1 with power output stage, Ignition coil 2 with power output stage, Ignition coil 3 with power output stage, Ignition coil 4 with power output stage, Spark plugs...................................................................................................................................................................................................................................................................................................................6495
9. Engine speed sensor, Charge air pressure sensor, Camshaft position sensor, Knock sensor 1, Fuel pressure sensor, Engine control module...................................................................................................................................................................................................................................................................................................................................................................................6496
10. Intake air temperature sensor, Engine coolant temperature sensor, Intake manifold runner position sensor, Engine control module, Cylinder 1 fuel injector, Cylinder 2 fuel injector, Fuel pressure regulator valve......................................................................................................................................................................................................................................................................................................6497
11. Accelerator pedal position sensor, Accelerator pedal position sensor 2, Engine control module, Cylinder 3 fuel injector, Cylinder 4 fuel injector, EVAP canister purge regulator valve 1, Turbocharger recirculation valve..............................................................................................................................................................................................................................................................................................6498
12. Oxygen sensor after catalytic converter, Engine control module, Wastegate bypass regulator valve, Camshaft adjustment valve 1, Intake manifold runner control valve, Oil pressure regulation valve......................................................................................................................................................................................................................................................................................................................6499
13. Brake lamp switch, Heated oxygen sensor, Engine control module, Leak detection pump.....................................................................................................................................................................................................................................................................................................................................................................................................................................6500
14. Clutch position sensor, Vehicle electrical control module system, Engine control module.................................................................................................................................................................................................................................................................................................................................................................................................................................6501
15. Vehicle electrical control module system, Data bus on board diagnostic interface........................................................................................................................................................................................................................................................................................................................................................................................................................................6502
16. Oil pressure switch, Reduced oil pressure switch, Fuel gauge, Engine coolant temperature gauge, Engine coolant level sensor, Multifunction indicator, Instrument cluster control module, Malfunction indicator lamp, Electronic power control malfunction i
dicator lamp................................................................................................................................................................................................................................................6503
059 -
Headlamps Bixenon HID with range control and cornering lamp , (8Q5),(8Q6)................................................................................................................................................................................................................................................................................................................................................................................................................................................6504
1.
Headlamps Bixenon HID with range control and cornering lamp , (8Q5),(8Q6)...............................................................................................................................................................................................................................................................................................................................................................................................................................................6504
2. Terminal 15 power supply relay, Vehicle electrical control module system, Fuse panel B, Fuse panel C.....................................................................................................................................................................................................................................................................................................................................................................................................................6505
3. Left HID lamp ballast, Vehicle electrical control module system, Left HID headlamp bulb, Left front fog lamp bulb, Left cornering lamp bulb, Left daytime running lamp bulb, Left position lamp bulb, Left front turn signal bulb, Left low beam headlamp re lector motor................................................................................................................................................................................................................................................6506
4. Left swivel module position sensor, Vehicle electrical control module system, Left headlamp power output module, Left headlamp beam adjustment motor, Left adaptive cornering lamp motor.................................................................................................................................................................................................................................................................................................................................6507
5. Left rear level control system sensor, Vehicle electrical control module system, Data bus on board diagnostic interface, Cornering lamp and headlamp range control module................................................................................................................................................................................................................................................................................................................................................6508
6. Right swivel module position sensor, Vehicle electrical control module system, Right headlamp power output module, Right headlamp beam adjustment motor, Right adaptive cornering lamp motor.............................................................................................................................................................................................................................................................................................................................6509
7. Right HID lamp ballast, Vehicle electrical control module system, Right HID headlamp bulb, Right front fog lamp bulb, Right cornering lamp bulb, Right daytime running lamp bulb, Right front turn signal bulb, Right low beam headlamp reflector motor..................................................................................................................................................................................................................................................................6510
8. Vehicle electrical control module system, Lighting control illumination bulb.............................................................................................................................................................................................................................................................................................................................................................................................................................................6511
060 -
Tire pressure monitoring , (7K4).........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6512
1.
Tire pressure monitoring , (7K4)........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6512
2. Instrument cluster control module........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6513
063 -
Headlamps Bixenon HID with range control, cornering lamp, LED daytime running lamps , (8K1),(8K2)........................................................................................................................................................................................................................................................................................................................................................................................................................6514
1.
Headlamps Bixenon HID with range control, cornering lamp, LED daytime running lamps , (8K1),(8K2).......................................................................................................................................................................................................................................................................................................................................................................................................................6514
2. Terminal 15 power supply relay, Fuse panel B, Fuse panel C...............................................................................................................................................................................................................................................................................................................................................................................................................................................................6515
3. Left HID lamp ballast, Left HID headlamp bulb, Left front fog lamp bulb, Left cornering lamp bulb, Left daytime running lamp and position lamp LED module, Left front turn signal bulb, Left low beam headlamp reflector motor...........................................................................................................................................................................................................................................................................................6516
4. Left swivel module position sensor, Left headlamp power output module, Left headlamp beam adjustment motor, Left adaptive cornering lamp motor...........................................................................................................................................................................................................................................................................................................................................................................6517
5. Left rear level control system sensor, Data bus on board diagnostic interface, Cornering lamp and headlamp range control module..........................................................................................................................................................................................................................................................................................................................................................................................6518
6. Right swivel module position sensor, Right headlamp power output module, Right headlamp beam adjustment motor, Right adaptive cornering lamp motor.......................................................................................................................................................................................................................................................................................................................................................................6519
7. Right HID lamp ballast, Right HID headlamp bulb, Right front fog lamp bulb, Right cornering lamp bulb, Right daytime running lamp and position lamp LED module, Right front turn signal bulb, Right low beam headlamp reflector motor....................................................................................................................................................................................................................................................................................6520
8. Lighting control illumination bulb.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6521
064 -
E-box High fuse assignment...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6522
1.
E-box High fuse assignment..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6522
2. Battery, Starter, Generator..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6523
3. Fuse panel B, Fuse 1 (on fuse panel B), Fuse 2 (on fuse panel B), Fuse 4 (on fuse panel B), Fuse 5 (on fuse panel B).....................................................................................................................................................................................................................................................................................................................................................................................................6524
4. Fuse panel B, Fuse 31 (on fuse panel B), Fuse 47 (on fuse panel B), Fuse 48 (on fuse panel B), Fuse 52 (on fuse panel B), Fuse 53 (on fuse panel B)......................................................................................................................................................................................................................................................................................................................................................................6525
5. Motronic engine control module power supply relay, Auxiliary engine coolant pump relay, Fuse panel B, Fuse 15 (on fuse panel B), Fuse 28 (on fuse panel B), Fuse 29 (on fuse panel B)....................................................................................................................................................................................................................................................................................................................................6526
6. Fuse panel B, Fuse 27 (on fuse panel B), Fuse 38 (on fuse panel B), Fuse 39 (on fuse panel B), Fuse 40 (on fuse panel B), Fuse 42 (on fuse panel B)......................................................................................................................................................................................................................................................................................................................................................................6527
7. Fuse panel B, Fuse 17 (on fuse panel B), Fuse 18 (on fuse panel B), Fuse 23 (on fuse panel B), Fuse 24 (on fuse panel B).................................................................................................................................................................................................................................................................................................................................................................................................6528
8. Radio/navigation display unit control module, Engine component power supply relay, Fuse panel B, Fuse 19 (on fuse panel B), Fuse 20 (on fuse panel B), Fuse 49 (on fuse panel B).........................................................................................................................................................................................................................................................................................................................................6529
9. Fuse panel B, Fuse 7 (on fuse panel B), Fuse 9 (on fuse panel B), Fuse 11 (on fuse panel B), Fuse 12 (on fuse panel B), Oxygen sensor heater, Heater for oxygen sensor 1 after catalytic converter.......................................................................................................................................................................................................................................................................................................................6530
067 -
2.0L diesel engine , CJAA................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6531
1.
2.0L diesel engine , CJAA...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6531
2. Battery, Starter, Generator, Fuse 1 (on fuse panel A), Fuse 5 (on fuse panel A), Fuse 27 (on fuse panel C)...............................................................................................................................................................................................................................................................................................................................................................................................................6532
3. Terminal 15 power supply relay, Terminal 50 power supply relay, Fuse 1 (on fuse panel C), Fuse 2 (on fuse panel C).......................................................................................................................................................................................................................................................................................................................................................................................................6533
4. Automatic glow time control module, Connection bridge....................................................................................................................................................................................................................................................................................................................................................................................................................................................................6534
5. Fuel level sensor, Transfer fuel pump, Fuel pump relay, Terminal 30 power supply relay, Fuel primer relay................................................................................................................................................................................................................................................................................................................................................................................................................6535
6. Engine control module....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6536
7. Charge air pressure sensor, Intake air temperature sensor, Accelerator pedal position sensor, Accelerator pedal position sensor 2, Engine control module.................................................................................................................................................................................................................................................................................................................................................................6537
8. Cylinder 1 internal pressure sensor, Cylinder 2 internal pressure sensor, Cylinder 3 internal pressure sensor, Engine control module, Glow plug 1, Glow plug 2, Glow plug 3..............................................................................................................................................................................................................................................................................................................................................6538
9. Throttle position sensor, Mass airflow sensor, Cylinder 4 internal pressure sensor, Throttle valve control module, Engine control module, Glow plug 4....................................................................................................................................................................................................................................................................................................................................................................6539
10. Heated oxygen sensor, Oxygen sensor after catalytic converter, Engine control module....................................................................................................................................................................................................................................................................................................................................................................................................................................6540
11. Engine coolant temperature sensor on radiator outlet, Exhaust gas temperature sensor 1, Exhaust gas temperature sensor 2, Exhaust gas temperature sensor 3, Exhaust gas temperature sensor 4, Engine control module.....................................................................................................................................................................................................................................................................................................6541
12. Exhaust pressure sensor 1, Differential pressure sensor, Engine control module, Exhaust door control unit, Cylinder 1 fuel injector.....................................................................................................................................................................................................................................................................................................................................................................................6542
13. Engine speed sensor, Fuel temperature sensor, Engine control module, Cylinder 2 fuel injector, Cylinder 3 fuel injector, Cylinder 4 fuel injector, Fuel pressure regulator valve, Fuel metering valve...................................................................................................................................................................................................................................................................................................................6543
14. EGR potentiometer, Fuel pressure sensor, Exhaust gas recirculation position sensor 2, Charge air pressure actuator position sensor, Engine control module, EGR vacuum regulator solenoid valve, Valve 2 for EGR.........................................................................................................................................................................................................................................................................................................6544
15. Camshaft position sensor, Engine coolant temperature sensor, Intake manifold runner position sensor, Engine control module, Wastegate bypass regulator valve, EGR cooler switch-over valve, Intake flap motor...........................................................................................................................................................................................................................................................................................................6545
16. EGR temperature sensor, Fuel pump relay 2, Engine control module, Positive crankcase ventilation heating element, Fuel pump 2...........................................................................................................................................................................................................................................................................................................................................................................................6546
17. Brake lamp switch, Clutch position sensor, Engine control module........................................................................................................................................................................................................................................................................................................................................................................................................................................................6547
18. Data bus on board diagnostic interface..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6548
19. Fuel gauge, Engine coolant temperature gauge, Engine coolant level sensor, Multifunction indicator, Instrument cluster control module, Data bus on board diagnostic interface, Glow plug indicator lamp, Diesel particulate filter indicator lamp.......................................................................................................................................................................................................................................................................6549
20. Oil pressure switch, Instrument cluster control module..................................................................................................................................................................................................................................................................................................................................................................................................................................................................6550
070 -
Anti-Lock Brake System (ABS) with EDL and ASR , (1AS),(1AT)..............................................................................................................................................................................................................................................................................................................................................................................................................................................................6551
1.
Anti-Lock Brake System (ABS) with EDL and ASR , (1AS),(1AT).............................................................................................................................................................................................................................................................................................................................................................................................................................................................6551
2. Left front ABS wheel speed sensor, ABS control module, Terminal 15 power supply relay, Fuse panel B, Fuse panel C........................................................................................................................................................................................................................................................................................................................................................................................................6552
3. ASR switch, Right rear ABS wheel speed sensor, Right front ABS wheel speed sensor, Left rear ABS wheel speed sensor, ABS control module..................................................................................................................................................................................................................................................................................................................................................................................6553
4. Tire pressure monitoring display button, ABS control module, Vehicle electrical control module system....................................................................................................................................................................................................................................................................................................................................................................................................................6554
5. Parking brake indicator lamp switch, Left front brake pad wear sensor, Instrument cluster control module, Vehicle electrical control module system, Data bus on board diagnostic interface, ABS indicator lamp, Traction control indicator lamp, Brake system indicator lamp, Tire pressure monitoring display indicator lamp............................................................................................................................................................................................6555
6. Brake fluid level warning switch, Instrument cluster control module......................................................................................................................................................................................................................................................................................................................................................................................................................................................6556
071 -
Anti-Lock Brake System (ABS) with EDL and ASR and ESP , (1AS),(1AT)......................................................................................................................................................................................................................................................................................................................................................................................................................................................6557
1.
Anti-Lock Brake System (ABS) with EDL and ASR and ESP , (1AS),(1AT).....................................................................................................................................................................................................................................................................................................................................................................................................................................................6557
2. ABS control module, Terminal 15 power supply relay, Fuse panel B, Fuse panel C...........................................................................................................................................................................................................................................................................................................................................................................................................................................6558
3. Right rear ABS wheel speed sensor, Right front ABS wheel speed sensor, Left rear ABS wheel speed sensor, Left front ABS wheel speed sensor, Vacuum sensor, ABS control module............................................................................................................................................................................................................................................................................................................................................6559
4. ASR/ESP button, Tire pressure monitoring display button, ABS control module..............................................................................................................................................................................................................................................................................................................................................................................................................................................6560
5. Instrument cluster control module, Vehicle electrical control module system, Data bus on board diagnostic interface......................................................................................................................................................................................................................................................................................................................................................................................................6561
6. Brake fluid level warning switch, Left front brake pad wear sensor, Warning buzzer and tone, Instrument cluster control module, ABS indicator lamp, Brake system indicator lamp, ASR/ESP indicator lamp, Tire pressure monitoring display indicator lamp.................................................................................................................................................................................................................................................................6562
074 -
Automatic transmission - DSG 02E , (G1A).................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6563
1.
Automatic transmission - DSG 02E , (G1A)................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6563
2. Terminal 15 power supply relay, Fuse 1 (on fuse panel A), Fuse 2 (on fuse panel C), Fuse 5 (on fuse panel A), Fuse 14 (on fuse panel C)..................................................................................................................................................................................................................................................................................................................................................................................6564
3. Transmission input speed sensor, Clutch oil temperature sensor, DSG transmission Mechatronic, Solenoid valve 1, Solenoid valve 2, Solenoid valve 4, Solenoid valve 5, Fuse panel B.......................................................................................................................................................................................................................................................................................................................................6565
4. Selector lever, Selector lever park position lock switch, Automatic transmission hydraulic pressure sensor 1, Automatic transmission hydraulic pressure sensor 2, Gear position distance sensor 1, DSG transmission Mechatronic, Shift lock solenoid, Automa ic transmission pressure regulating valve 1, Automatic transmission pressure regulating valve 2, Automatic transmission pressure regulating valve 3, Automatic transmission pressure regulating valve 4, Transmission range display.........................6566
5. Selector lever, Transmission fluid temperature sensor, Transmission output speed sensor, Transmission output speed sensor 2, Gear position distance sensor 2, Gear position distance sensor 3, Gear position distance sensor 4, Driveshaft speed sensor 1, D
iveshaft speed sensor 2, Temperature sensor in control module, DSG transmission Mechatronic, Automatic transmission pressure regulating valve 5, Automatic transmission pressure regulating valve 6, Transmission range display.............................6567
6. Multifunction indicator, Instrument cluster control module, Data bus on board diagnostic interface.......................................................................................................................................................................................................................................................................................................................................................................................................................6568
076 -
Parking distance control without parallel parking assistance (park assist) , (7X5),(7X6).................................................................................................................................................................................................................................................................................................................................................................................................................................6569
1.
Parking distance control without parallel parking assistance (park assist) , (7X5),(7X6)................................................................................................................................................................................................................................................................................................................................................................................................................................6569
2. Terminal 15 power supply relay, Parking aid control module, Data bus on board diagnostic interface, Fuse 4 (on fuse panel C), Fuse 7 (on fuse panel B)...................................................................................................................................................................................................................................................................................................................................................................6570
3. Left rear parking aid sensor, Left rear center parking aid sensor, Right rear center parking aid sensor, Right rear parking aid sensor, Rear parking aid warning buzzer, Parking aid control module......................................................................................................................................................................................................................................................................................................................6571
4. Right front parking aid sensor, Right front center parking aid sensor, Left front center parking aid sensor, Left front parking aid sensor, Front parking aid warning buzzer, Parking aid control module.................................................................................................................................................................................................................................................................................................................6572
5. Parking aid button, Parking aid control module...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6573
077 -
Parking distance control, with park assist...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6574
1.
Parking distance control, with park assist..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6574
2. Terminal 15 power supply relay, Parallel parking assistance control module, Fuse 4 (on fuse panel C), Fuse 7 (on fuse panel B)...........................................................................................................................................................................................................................................................................................................................................................................................6575
3. Left rear parking aid sensor, Left rear center parking aid sensor, Right rear center parking aid sensor, Right rear parking aid sensor, Rear parking aid warning buzzer, Parallel parking assistance control module......................................................................................................................................................................................................................................................................................................6576
4. Parking aid button, Parallel parking assistance button, Data bus on board diagnostic interface, Parallel parking assistance control module...............................................................................................................................................................................................................................................................................................................................................................................6577
5. Left front center parking aid sensor, Left front parking aid sensor, Left front parallel parking assistance sensor, Front parking aid warning buzzer, Parallel parking assistance control module.........................................................................................................................................................................................................................................................................................................................6578
6. Right front parking aid sensor, Right front center parking aid sensor, Right front parallel parking assistance sensor, Parallel parking assistance control module........................................................................................................................................................................................................................................................................................................................................................6579
078 -
Power steering, electromechanical , (1N3),(QZ0)..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6580
1.
Power steering, electromechanical , (1N3),(QZ0).........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6580
2. Terminal 15 power supply relay, Power steering control module, Fuse 2 (on fuse panel C), Fuse 2 (on fuse panel A), Fuse 7 (on fuse panel B), Electromechanical power steering motor......................................................................................................................................................................................................................................................................................................................................6581
3. Steering angle sensor, Steering torque sensor, Power steering control module, Data bus on board diagnostic interface.....................................................................................................................................................................................................................................................................................................................................................................................................6582
4. Instrument cluster control module, Data bus on board diagnostic interface, Electromechanical power steering indicator lamp...............................................................................................................................................................................................................................................................................................................................................................................................6583
079 -
Climatic , (KH6),(9AP)...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6584
1.
Climatic , (KH6),(9AP)..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6584
2. Load reduction relay, Terminal 15 power supply relay, Fuse panel B, Fuse panel C.........................................................................................................................................................................................................................................................................................................................................................................................................................................6585
3. High pressure sensor, Center vent temperature sensor, A/C control module, A/C compressor regulator valve, Recirculation door motor.......................................................................................................................................................................................................................................................................................................................................................................................6586
4. Footwell vent temperature sensor, Evaporator vent temperature sensor, A/C control module, Temperature control door motor, Air distribution door motor....................................................................................................................................................................................................................................................................................................................................................................6587
5. Fresh air blower switch, A/C control module, Fresh air blower series resistor with fuse, Fresh air blower................................................................................................................................................................................................................................................................................................................................................................................................................6588
6. Vehicle electrical control module system, Data bus on board diagnostic interface.........................................................................................................................................................................................................................................................................................................................................................................................................................................6589
080 -
Climatronic , (9AK)......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6590
1.
Climatronic , (9AK).....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6590
2. Climatronic control module, Terminal 15 power supply relay, Fuse 1 (on fuse panel A), Fuse 4 (on fuse panel C), Fuse 5 (on fuse panel A), Fuse 7 (on fuse panel B), Fuse 14 (on fuse panel C), Fuse 22 (on fuse panel C).................................................................................................................................................................................................................................................................................................6591
3. High pressure sensor, Air quality sensor, Climatronic control module, Left temperature control door motor................................................................................................................................................................................................................................................................................................................................................................................................................6592
4. Climatronic control module, Right temperature control door motor, Fresh air/recirculating air/back pressure door motor, Front air distribution door motor................................................................................................................................................................................................................................................................................................................................................................6593
5. Sunlight photo sensor, Sunlight photo sensor 2, Left vent temperature sensor, Right vent temperature sensor, Climatronic control module, Defroster door motor............................................................................................................................................................................................................................................................................................................................................................6594
6. Fresh air blower control module, Climatronic control module, Vehicle electrical control module system, Data bus on board diagnostic interface, Fresh air blower..........................................................................................................................................................................................................................................................................................................................................................6595
082 -
Auxiliary heater (PTC), diesel engine , (7E6)............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6596
1.
Auxiliary heater (PTC), diesel engine , (7E6)...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6596
2. Terminal 30 power supply relay, Low heat output relay, High heat output relay, Engine control module, Fuse 1 (on fuse panel A), Fuse 4 (on fuse panel A), Fuse 6 (on fuse panel A), Fuse panel B, Auxiliary heater heating element.......................................................................................................................................................................................................................................................................................6597
3. Fresh air blower switch, A/C control module, Fresh air blower series resistor with fuse, Fresh air blower................................................................................................................................................................................................................................................................................................................................................................................................................6598
083 -
Washer system, headlamps , (8X1).........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6599
1.
Washer system, headlamps , (8X1)........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6599
2. Headlamp washer relay, Headlamp washer pump..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6600
3. Windshield wiper intermittent mode switch, Rear window wiper switch, Windshield and headlamp washer pump switch, Windshield washer fluid level sensor, Instrument cluster control module, Steering column electronics control module, Data bus on board diag
ostic interface, Windshield washer fluid level indicator lamp...............................................................................................................................................................................................6601
088 -
2.0L gasoline engine , CBFA..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6602
1.
2.0L gasoline engine , CBFA.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6602
2. Battery, Starter, Generator, Fuse 1 (on fuse panel A)....................................................................................................................................................................................................................................................................................................................................................................................................................................................................6603
3. Terminal 50 power supply relay, Starter relay 1, Starter relay 2.........................................................................................................................................................................................................................................................................................................................................................................................................................................................6604
4. Terminal 15 power supply relay, Fuse 5 (on fuse panel A), Fuse panel B...................................................................................................................................................................................................................................................................................................................................................................................................................................................6605
5. Fuel level sensor, Transfer fuel pump, Secondary air injection pump relay, Fuel pump control module, Fuse panel B, Secondary air injection pump motor....................................................................................................................................................................................................................................................................................................................................................................6606
6. Motronic engine control module power supply relay, Fuse panel B..........................................................................................................................................................................................................................................................................................................................................................................................................................................................6607
7. Steering column electronics control module, Engine control module........................................................................................................................................................................................................................................................................................................................................................................................................................................................6608
8. Engine coolant temperature sensor, Coolant circulation pump relay, Engine control module, After-run coolant pump.........................................................................................................................................................................................................................................................................................................................................................................................................6609
9. Engine control module, Ignition coil 1 with power output stage, Ignition coil 2 with power output stage, Ignition coil 3 with power output stage, Ignition coil 4 with power output stage, Spark plugs...................................................................................................................................................................................................................................................................................................................6610
10. Engine speed sensor, Throttle valve control module, Engine control module, Fuel pressure regulator valve................................................................................................................................................................................................................................................................................................................................................................................................................6611
11. Charge air pressure sensor, Camshaft position sensor, Knock sensor 1, Fuel pressure sensor, Intake manifold runner position sensor, Engine control module...............................................................................................................................................................................................................................................................................................................................................................6612
12. Intake air temperature sensor, Intake manifold runner position sensor, Secondary air injection sensor 1, Engine control module, Cylinder 1 fuel injector, Cylinder 2 fuel injector, Cylinder 3 fuel injector, Cylinder 4 fuel injector..................................................................................................................................................................................................................................................................................6613
13. Accelerator pedal position sensor, Accelerator pedal position sensor 2, Engine control module, Wastegate bypass regulator valve, EVAP canister purge regulator valve 1, Turbocharger recirculation valve................................................................................................................................................................................................................................................................................................................6614
14. Map controlled engine cooling thermostat, Mass airflow sensor, Engine coolant temperature sensor on radiator outlet, Engine control module, Secondary air injection solenoid valve, Camshaft adjustment valve 1, Intake manifold runner control valve...................................................................................................................................................................................................................................................................6615
15. Heated oxygen sensor, Radiator identification sensor, Engine control module, Leak detection pump........................................................................................................................................................................................................................................................................................................................................................................................................................6616
16. Brake lamp switch, Heated oxygen sensor 2, Oxygen sensor after catalytic converter, Engine control module...............................................................................................................................................................................................................................................................................................................................................................................................................6617
17. Clutch position sensor, Engine control module...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6618
18. Engine control module...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6619
19. Multifunction indicator, Data bus on board diagnostic interface.........................................................................................................................................................................................................................................................................................................................................................................................................................................................6620
20. Oil pressure switch, Fuel gauge, Engine coolant temperature gauge, Engine coolant level sensor, Malfunction indicator lamp..............................................................................................................................................................................................................................................................................................................................................................................................6621
098 -
Multifunction steering wheel.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6622
1.
Multifunction steering wheel............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6622
2. Battery, Battery monitoring control module, Voltage stabilizer...........................................................................................................................................................................................................................................................................................................................................................................................................................................................6623
3. Terminal 15 power supply relay, Fuse panel B, Fuse panel C...............................................................................................................................................................................................................................................................................................................................................................................................................................................................6624
4. Multifunction indicator, Instrument cluster control module, Data bus on board diagnostic interface.......................................................................................................................................................................................................................................................................................................................................................................................................................6625
5. Signal horn activation, Steering column electronics control module, Driver airbag igniter................................................................................................................................................................................................................................................................................................................................................................................................................................6626
6. Turn signal switch, Headlamp dimmer/flasher switch, Cruise control switch, Cruise control -SET- button, Left multifunction buttons on steering wheel, tiptronic downshift button, Signal horn activation, Multifunction steering wheel control module, Steering column electronics control module........................................................................................................................................................................................................................6627
7. Ignition/starter switch, Left multifunction buttons on steering wheel, Right multifunction buttons on steering wheel, tiptronic upshift button, Multifunction steering wheel control module, Steering column electronics control module, Ignition switch key lock solenoid...............................................................................................................................................................................................................................................6628
099 -
Standard equipment (NAR).................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6629
1.
Standard equipment (NAR)................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6629
2. Battery, Terminal 15 power supply relay, Fuse 1 (on fuse panel A), Fuse 5 (on fuse panel A), Fuse panel B................................................................................................................................................................................................................................................................................................................................................................................................................6630
3. Fuse panel B, Fuse panel C...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6631
4. Fuse panel C.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6632
5. Load reduction relay, Fuse panel C.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6633
6. Ignition/starter switch, Steering column electronics control module, Ignition switch key lock solenoid...................................................................................................................................................................................................................................................................................................................................................................................................................6634
7. Signal horn activation, Steering column electronics control module, Driver airbag igniter................................................................................................................................................................................................................................................................................................................................................................................................................................6635
8. Turn signal switch, Headlamp dimmer/flasher switch, Windshield wiper intermittent mode switch, Rear window wiper switch, Windshield wiper intermittent regulator, Windshield and headlamp washer pump switch, Cruise control switch, Multifunction indicator selection switch, Multifunction indicator memory switch, Cruise control -SET- button, Steering column electronics control module............................................................................................................................6636
9. Left front fog lamp bulb, Left cornering lamp bulb, Left daytime running lamp bulb, Left position lamp bulb, Left front turn signal bulb, Left low beam headlamp bulb, Left high beam headlamp bulb, Left front side marker lamp bulb....................................................................................................................................................................................................................................................................................6637
10. Instrument panel and switch illumination dimmer switch, Back-up lamp switch, Engine hood contact switch, High tone horn, Low tone horn, Dual tone horn relay............................................................................................................................................................................................................................................................................................................................................................6638
11. Right front fog lamp bulb, Right cornering lamp bulb, Right position lamp bulb, Right front turn signal bulb, Right low beam headlamp bulb, Right high beam headlamp bulb, Right front side marker lamp bulb............................................................................................................................................................................................................................................................................................................6639
12. Light switch, Fog lamp switch, Fog lamp indicator lamp, Automatic light control indicator lamp..........................................................................................................................................................................................................................................................................................................................................................................................................................6640
13. Right tail lamp bulb, Left tail lamp bulb, Left rear turn signal bulb, Right rear turn signal bulb, Left back-up lamp bulb, Right back-up lamp bulb, Left brake/tail lamp bulb, Right brake/tail lamp bulb..............................................................................................................................................................................................................................................................................................................6641
14. Rear window defogger relay, Driver exterior rearview mirror turn signal bulb, Front passenger exterior rearview mirror turn signal bulb, High-mounted brake lamp bulb, Left license plate lamp, Right license plate lamp, Rear window defogger..........................................................................................................................................................................................................................................................................6642
15. Emergency flasher button, Left washer nozzle heater, Right washer nozzle heater.........................................................................................................................................................................................................................................................................................................................................................................................................................................6643
16. Rain/light recognition sensor, Wiper motor control module, Rear window wiper motor, Windshield and rear window washer pump, Driver windshield wiper motor...............................................................................................................................................................................................................................................................................................................................................................6644
17. Glove compartment lamp switch, Brake lamp switch, Luggage compartment lamp, Glove compartment lamp......................................................................................................................................................................................................................................................................................................................................................................................................................6645
18. Front interior lamp, Left rear reading lamp, Right rear reading lamp, Front passenger reading lamp, Driver reading lamp, Rear interior lamp.............................................................................................................................................................................................................................................................................................................................................................................6646
19. Driver vanity mirror lamp contact switch, Front passenger vanity mirror lamp contact switch, Blocking diode, Cigarette lighter illumination bulb, Cigarette lighter, 12 V socket, Left footwell lamp, Right footwell lamp, Front passenger vanity mirror lamp, Driver vanity mirror lamp................................................................................................................................................................................................................................6647
20. Fresh air blower switch, Heater/heat output switch, Fresh air blower series resistor with fuse, Fresh air blower, Recirculation door motor..............................................................................................................................................................................................................................................................................................................................................................................6648
21. Data bus on board diagnostic interface, Diagnostic connection...........................................................................................................................................................................................................................................................................................................................................................................................................................................................6649
22. Anti-theft immobilizer reader coil, Brake fluid level warning switch, Warning buzzer and tone, Instrument cluster control module, Cruise control indicator lamp, Anti-theft immobilizer indicator lamp, Door ajar indicator lamp, Lamp failure indicator lamp, Hood -open- indicator lamp...............................................................................................................................................................................................................................6650
23. Parking brake indicator lamp switch, Tachometer, Speedometer, Windshield washer fluid level sensor, Left front brake pad wear sensor, Instrument cluster control module, High beam indicator lamp, Windshield washer fluid level indicator lamp.........................................................................................................................................................................................................................................................................6651
24. Fuel gauge, Engine coolant temperature gauge, Outside air temperature sensor, Engine coolant level sensor, Multifunction indicator, Instrument cluster control module, Position lamp indicator lamp, Rear fog lamp indicator lamp, Engine electronics indicator lamp, Odometer display..................................................................................................................................................................................................................................6652
100 -
Cell phone system........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6653
1.
Cell phone system.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6653
2. Terminal 15 power supply relay, Fuse panel B.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6654
3. Cell phone operating electronics control module, Voltage stabilizer, Data bus on board diagnostic interface, Fuse 2 (on fuse panel C), Fuse 48 (on fuse panel C).........................................................................................................................................................................................................................................................................................................................................................6655
4. Cell phone operating electronics control module, Radio/navigation display unit control module, Radio, Telephone microphone...............................................................................................................................................................................................................................................................................................................................................................................................6657
5. Telematics button module, Cell phone operating electronics control module, Telephone baseplate...........................................................................................................................................................................................................................................................................................................................................................................................................................6658
6. Cell phone operating electronics control module, GPS antenna, Telephone antenna, Auxiliary engine coolant heater radio frequency receiver, Auxiliary heater antenna......................................................................................................................................................................................................................................................................................................................................................6659
101 -
Headlamps Bixenon HID with range control, cornering lamp, LED daytime running lamps , (8G1),(8K1),(8K2)..................................................................................................................................................................................................................................................................................................................................................................................................................6660
1.
Headlamps Bixenon HID with range control, cornering lamp, LED daytime running lamps , (8G1),(8K1),(8K2).................................................................................................................................................................................................................................................................................................................................................................................................................6660
2. Terminal 15 power supply relay, Fuse panel B, Fuse panel C...............................................................................................................................................................................................................................................................................................................................................................................................................................................................6661
3. Left HID headlamp control module, Left HID headlamp bulb, Left front fog lamp bulb, Left cornering lamp bulb, Left daytime running lamp and position lamp LED module.....................................................................................................................................................................................................................................................................................................................................................6662
4. Left swivel module position sensor, Sensor for left variable headlamp positioning motor, Left headlamp power output module, Left front turn signal bulb, Left low beam headlamp reflector motor, Left adaptive cornering lamp motor......................................................................................................................................................................................................................................................................................6663
5. Left rear level control system sensor, Data bus on board diagnostic interface, Left headlamp power output module, Cornering lamp and headlamp range control module, Left headlamp beam adjustment motor..................................................................................................................................................................................................................................................................................................................6664
6. Right swivel module position sensor, Sensor for right variable headlamp positioning motor, Right headlamp power output module, Right headlamp beam adjustment motor, Right low beam headlamp reflector motor.............................................................................................................................................................................................................................................................................................................6665
7. Sensor for right variable headlamp positioning motor, Right daytime running lamp and position lamp LED module, Right front turn signal bulb, Right adaptive cornering lamp motor.........................................................................................................................................................................................................................................................................................................................................6666
8. Right HID headlamp control module, Right HID headlamp bulb, Right front fog lamp bulb, Lighting control illumination bulb, Right cornering lamp bulb.....................................................................................................................................................................................................................................................................................................................................................................6667
102 -
2.5L gasoline engine , CBTA, CBUA........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6668
1.
2.5L gasoline engine , CBTA, CBUA.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6668
2. Battery, Starter, Generator, Fuse 1 (on fuse panel A), Fuse 2 (on fuse panel C), Fuse 5 (on fuse panel A), Fuse 27 (on fuse panel C).....................................................................................................................................................................................................................................................................................................................................................................................6669
3. Fuel pump relay, Terminal 15 power supply relay, Terminal 50 power supply relay, Fuse panel B............................................................................................................................................................................................................................................................................................................................................................................................................................6670
4. Secondary air injection pump relay, Fuse panel B, Secondary air injection pump motor.....................................................................................................................................................................................................................................................................................................................................................................................................................................6671
5. Motronic engine control module power supply relay, Engine control module, Fuse panel B...................................................................................................................................................................................................................................................................................................................................................................................................................................6672
6. Engine control module, Ignition coil 1 with power output stage, Ignition coil 2 with power output stage, Ignition coil 3 with power output stage, Ignition coil 4 with power output stage, Spark plugs...................................................................................................................................................................................................................................................................................................................6673
7. Engine coolant temperature sensor, Engine coolant temperature sensor on radiator outlet, Throttle valve control module, Engine control module, Ignition coil 5 with power output stage...................................................................................................................................................................................................................................................................................................................................6674
8. Camshaft position sensor, Intake air temperature sensor, Knock sensor 1, Knock sensor 2, Manifold absolute pressure sensor, Secondary air injection sensor 1, Engine control module......................................................................................................................................................................................................................................................................................................................................6675
9. Engine speed sensor, Camshaft position sensor, Engine control module, Cylinder 1 fuel injector, Cylinder 2 fuel injector, Cylinder 3 fuel injector, Cylinder 4 fuel injector, Cylinder 5 fuel injector, Leak detection pump..............................................................................................................................................................................................................................................................................................6676
10. Oxygen sensor after catalytic converter, Center oxygen sensor for bank 1 catalytic converter, Engine control module, EVAP canister purge regulator valve 1, Secondary air injection solenoid valve, Camshaft adjustment valve 1.........................................................................................................................................................................................................................................................................................6677
11. Heated oxygen sensor, Accelerator pedal position sensor, Accelerator pedal position sensor 2, Center oxygen sensor for bank 1 catalytic converter, Engine control module................................................................................................................................................................................................................................................................................................................................................6678
12. Brake lamp switch, Clutch position sensor, Engine control module........................................................................................................................................................................................................................................................................................................................................................................................................................................................6679
13. Vehicle electrical control module system, Engine control module.........................................................................................................................................................................................................................................................................................................................................................................................................................................................6680
14. Multifunction indicator, Instrument cluster control module, Vehicle electrical control module system, Data bus on board diagnostic interface............................................................................................................................................................................................................................................................................................................................................................................6681
15. Oil pressure switch, Fuel level sensor, Fuel gauge, Engine coolant temperature gauge, Transfer fuel pump, Engine coolant level sensor, Instrument cluster control module................................................................................................................................................................................................................................................................................................................................................6682
103 -
Multifunction steering wheel.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6683
1.
Multifunction steering wheel............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6683
2. Battery, Battery monitoring control module, Voltage stabilizer...........................................................................................................................................................................................................................................................................................................................................................................................................................................................6684
3. Terminal 15 power supply relay, Fuse panel B, Fuse panel C...............................................................................................................................................................................................................................................................................................................................................................................................................................................................6685
4. Multifunction indicator, Instrument cluster control module, Data bus on board diagnostic interface.......................................................................................................................................................................................................................................................................................................................................................................................................................6686
5. Signal horn activation, Steering column electronics control module, Driver airbag igniter................................................................................................................................................................................................................................................................................................................................................................................................................................6687
6. Turn signal switch, Headlamp dimmer/flasher switch, Cruise control switch, Cruise control -SET- button, Left multifunction buttons on steering wheel, tiptronic downshift button, Signal horn activation, Multifunction steering wheel control module, Steering column electronics control module........................................................................................................................................................................................................................6688
7. Ignition/starter switch, Left multifunction buttons on steering wheel, Right multifunction buttons on steering wheel, tiptronic upshift button, Multifunction steering wheel control module, Steering column electronics control module, Ignition switch key lock solenoid...............................................................................................................................................................................................................................................6689
104 -
Radio navigation system..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6690
1.
Radio navigation system.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6690
2. Rear window defogger relay, Terminal 15 power supply relay, Fuse panel B, Fuse panel C...................................................................................................................................................................................................................................................................................................................................................................................................................................6691
3. Radio/navigation display unit control module, Voltage stabilizer, Radio, Fuse 5 (on fuse panel A), Fuse panel C..........................................................................................................................................................................................................................................................................................................................................................................................................6692
4. Radio/navigation display unit control module, Radio, External audio source connection, External multimedia device interface..............................................................................................................................................................................................................................................................................................................................................................................................6694
5. Cell phone operating electronics control module, Radio/navigation display unit control module, Data bus on board diagnostic interface, Radio, External multimedia device interface.......................................................................................................................................................................................................................................................................................................................................6695
6. Cell phone operating electronics control module, Radio/navigation display unit control module, Radio, Telephone microphone...............................................................................................................................................................................................................................................................................................................................................................................................6696
7. Radio/navigation display unit control module, Radio, Telephone baseplate.................................................................................................................................................................................................................................................................................................................................................................................................................................................6697
8. Radio/navigation display unit control module, Radio, Left front treble speaker, Left front bass speaker, Right front treble speaker, Right front bass speaker............................................................................................................................................................................................................................................................................................................................................................6698
9. Radio/navigation display unit control module, Radio, Left rear treble speaker, Left rear bass speaker....................................................................................................................................................................................................................................................................................................................................................................................................................6699
10. Radio/navigation display unit control module, Radio, Right rear treble speaker, Right rear bass speaker.................................................................................................................................................................................................................................................................................................................................................................................................................6700
11. Radio/navigation display unit control module, Radio, CD changer.........................................................................................................................................................................................................................................................................................................................................................................................................................................................6701
12. Radio/navigation display unit control module, Radio, GPS antenna, Telephone antenna, Auxiliary coolant heater radio frequency receiver, Auxiliary heater antenna........................................................................................................................................................................................................................................................................................................................................................6702
13. Radio/navigation display unit control module, Radio, Antenna, Left antenna module, Right antenna module, FM frequency filter in negative wire, FM frequency filter in positive wire, Rear window defogger...............................................................................................................................................................................................................................................................................................................6703
14. Amplifier, Left front treble speaker, Left front bass speaker, Right front treble speaker, Right front bass speaker.....................................................................................................................................................................................................................................................................................................................................................................................................6704
15. Amplifier, Left rear treble speaker, Left rear bass speaker.............................................................................................................................................................................................................................................................................................................................................................................................................................................................6705
16. Amplifier, Right rear treble speaker, Right rear bass speaker...........................................................................................................................................................................................................................................................................................................................................................................................................................................................6706
108 -
Standard equipment (NAR).................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6707
1.
Standard equipment (NAR)................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6707
2. Battery, Terminal 15 power supply relay, Fuse 1 (on fuse panel A), Fuse 5 (on fuse panel A), Fuse panel B................................................................................................................................................................................................................................................................................................................................................................................................................6708
3. Fuse panel B, Fuse panel C...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6709
4. Fuse panel C.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6710
5. Load reduction relay, Fuse panel C.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6711
6. Ignition/starter switch, Steering column electronics control module, Ignition switch key lock solenoid...................................................................................................................................................................................................................................................................................................................................................................................................................6712
7. Signal horn activation, Steering column electronics control module, Driver airbag igniter................................................................................................................................................................................................................................................................................................................................................................................................................................6713
8. Turn signal switch, Headlamp dimmer/flasher switch, Windshield wiper intermittent mode switch, Rear window wiper switch, Windshield wiper intermittent regulator, Windshield and headlamp washer pump switch, Cruise control switch, Multifunction indicator selection switch, Multifunction indicator memory switch, Cruise control -SET- button, Steering column electronics control module............................................................................................................................6714
9. Left front fog lamp bulb, Left cornering lamp bulb, Left daytime running lamp bulb, Left position lamp bulb, Left front turn signal bulb, Left low beam headlamp bulb, Left high beam headlamp bulb, Left front side marker lamp bulb....................................................................................................................................................................................................................................................................................6715
10. Instrument panel and switch illumination dimmer switch, Back-up lamp switch, Engine hood contact switch, High tone horn, Low tone horn, Dual tone horn relay............................................................................................................................................................................................................................................................................................................................................................6716
11. Right front fog lamp bulb, Right cornering lamp bulb, Right position lamp bulb, Right front turn signal bulb, Right low beam headlamp bulb, Right high beam headlamp bulb, Right front side marker lamp bulb............................................................................................................................................................................................................................................................................................................6717
12. Light switch, Fog lamp switch, Fog lamp indicator lamp, Automatic light control indicator lamp..........................................................................................................................................................................................................................................................................................................................................................................................................................6718
13. Right tail lamp bulb, Left tail lamp bulb, Left rear turn signal bulb, Right rear turn signal bulb, Left back-up lamp bulb, Right back-up lamp bulb, Left brake/tail lamp bulb, Right brake/tail lamp bulb..............................................................................................................................................................................................................................................................................................................6719
14. Rear window defogger relay, Driver exterior rearview mirror turn signal bulb, Front passenger exterior rearview mirror turn signal bulb, High-mounted brake lamp bulb, Left license plate lamp, Right license plate lamp, Rear window defogger..........................................................................................................................................................................................................................................................................6720
15. Emergency flasher button, Left washer nozzle heater, Right washer nozzle heater.........................................................................................................................................................................................................................................................................................................................................................................................................................................6721
16. Rain/light recognition sensor, Wiper motor control module, Rear window wiper motor, Windshield and rear window washer pump, Driver windshield wiper motor...............................................................................................................................................................................................................................................................................................................................................................6722
17. Glove compartment lamp switch, Brake lamp switch, Luggage compartment lamp, Glove compartment lamp......................................................................................................................................................................................................................................................................................................................................................................................................................6723
18. Front interior lamp, Left rear reading lamp, Right rear reading lamp, Front passenger reading lamp, Driver reading lamp, Rear interior lamp.............................................................................................................................................................................................................................................................................................................................................................................6724
19. Driver vanity mirror lamp contact switch, Front passenger vanity mirror lamp contact switch, Blocking diode, Cigarette lighter illumination bulb, Cigarette lighter, 12 V socket, Left footwell lamp, Right footwell lamp, Front passenger vanity mirror lamp, Driver vanity mirror lamp................................................................................................................................................................................................................................6725
20. Fresh air blower switch, Heater/heat output switch, Fresh air blower series resistor with fuse, Fresh air blower, Recirculation door motor..............................................................................................................................................................................................................................................................................................................................................................................6726
21. Data bus on board diagnostic interface, Diagnostic connection...........................................................................................................................................................................................................................................................................................................................................................................................................................................................6727
22. Anti-theft immobilizer reader coil, Brake fluid level warning switch, Warning buzzer and tone, Instrument cluster control module, Cruise control indicator lamp, Anti-theft immobilizer indicator lamp, Door ajar indicator lamp, Lamp failure indicator lamp, Hood -open- indicator lamp...............................................................................................................................................................................................................................6728
23. Parking brake indicator lamp switch, Tachometer, Speedometer, Windshield washer fluid level sensor, Left front brake pad wear sensor, Instrument cluster control module, High beam indicator lamp, Windshield washer fluid level indicator lamp.........................................................................................................................................................................................................................................................................6729
24. Fuel gauge, Engine coolant temperature gauge, Outside air temperature sensor, Engine coolant level sensor, Multifunction indicator, Instrument cluster control module, Position lamp indicator lamp, Rear fog lamp indicator lamp, Engine electronics indicator lamp, Odometer display..................................................................................................................................................................................................................................6730
109 -
Comfort system (NAR) , (0A1),(8G1).......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6731
1.
Comfort system (NAR) , (0A1),(8G1)......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6731
2. Terminal 15 power supply relay, Fuse panel B, Fuse 5 (on fuse panel A), Fuse panel C.....................................................................................................................................................................................................................................................................................................................................................................................................................................6732
3. Left front window regulator switch, Right front power window switch in driver door, Driver interior locking button, Driver door contact switch, Driver central locking lock unit, Driver door control module, Central locking -SAFE- indicator lamp, Driver door central locking system motor, Driver window regulator motor.............................................................................................................................................................................................6733
4. Mirror adjusting switch, Mirror selector switch, Exterior rearview mirror heating switch, Mirror folding switch, Exterior rearview mirror horizontal adjustment position sensor, Exterior rearview mirror vertical adjustment position sensor, Driver door control module, Driver exterior rearview mirror turn signal bulb, Driver mirror adjustment motor 2, Driver exterior rearview mirror folding motor, Heated driver exterior rearview mirror.....................................................................6734
5. Driver door control module, Front passenger exterior rearview mirror turn signal bulb, Driver entry lamp in exterior rearview mirror, Front passenger entry lamp in exterior rearview mirror, Driver automatic dimming exterior rearview mirror, Heated fron passenger exterior rearview mirror.........................................................................................................................................................................................................................6735
6. Front passenger door window regulator switch, Front passenger door contact switch, Front passenger central locking lock unit, Exterior rearview mirror horizontal adjustment position sensor, Exterior rearview mirror vertical adjustment position sensor, Front passenger side mirror adjustment motor 2, Front passenger door central locking system motor, Front passenger exterior rearview mirror folding motor, Front passenger window regulator motor............................................................6736
7. Release button in rear lid handle, Luggage compartment lamp switch, Central locking and anti-theft alarm system antenna, Rear lid unlock motor, Fuel filler door unlock motor, Luggage compartment lamp..................................................................................................................................................................................................................................................................................................................6737
8. Sunroof adjustment regulator, Sunroof button, Engine hood contact switch, Alarm horn, Power sunroof control module, Sunroof motor........................................................................................................................................................................................................................................................................................................................................................................................6738
9. Automatic dimming interior rearview mirror switch, Light recognition sensor, Automatic high beam assist control module, Automatic dimming interior rearview mirror.......................................................................................................................................................................................................................................................................................................................................................6739
110 -
Comfort system (NAR) , (0A2),(8G1).......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6740
1.
Comfort system (NAR) , (0A2),(8G1)......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6740
2. Fuse 5 (on fuse panel A), Fuse panel C...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6741
3. Terminal 15 power supply relay, Driver door control module, Fuse panel B, Fuse panel C, Driver window regulator motor....................................................................................................................................................................................................................................................................................................................................................................................................6742
4. Left front window regulator switch, Left rear window regulator switch in driver door, Right rear window regulator switch in driver door, Right front power window switch in driver door, Child safety lock button, Driver door contact switch, Driver central locking lock unit, Exterior rearview mirror horizontal adjustment position sensor, Exterior rearview mirror vertical adjustment position sensor, Driver door control module, Driver mirror adjustment motor 2, Driver door central locking system motor....6743
5. Left front window regulator switch, Right front power window switch in driver door, Driver interior locking button, Driver door control module, Central locking -SAFE- indicator lamp, Driver exterior rearview mirror turn signal bulb, Driver exterior rea
view mirror folding motor, Driver entry lamp in exterior rearview mirror, Driver automatic dimming exterior rearview mirror, Heated driver exterior rearview mirror.........................................................................................6744
6. Mirror adjusting switch, Mirror selector switch, Front passenger door window regulator switch, Exterior rearview mirror heating switch, Mirror folding switch, Driver door control module, Front passenger exterior rearview mirror turn signal bulb, Heated front passenger exterior rearview mirror....................................................................................................................................................................................................................6745
7. Front passenger door contact switch, Front passenger central locking lock unit, Exterior rearview mirror horizontal adjustment position sensor, Exterior rearview mirror vertical adjustment position sensor, Front passenger side mirror adjustment motor 2, Front passenger door central locking system motor, Front passenger exterior rearview mirror folding motor, Front passenger window regulator motor, Front passenger entry lamp in exterior rearview mirror..................................................6746
8. Left rear power window switch in left rear door, Left rear door contact switch, Left rear central locking lock unit, Left rear door control module, Right rear door control module, Left rear window regulator motor, Left rear central locking -lock- motor.............................................................................................................................................................................................................................................................6747
9. Right rear window switch in right rear door, Left rear door contact switch, Right rear door contact switch, Left rear central locking lock unit, Right rear central locking lock unit, Right rear door control module, Right rear window regulator motor, Le t rear central locking -lock- motor, Right rear central locking -lock- motor................................................................................................................................................................................6748
10. Release button in rear lid handle, Luggage compartment lamp switch, Right rear door contact switch, Right rear central locking lock unit, Rear lid unlock motor, Right rear central locking -lock- motor, Luggage compartment lamp......................................................................................................................................................................................................................................................................................6749
11. Sunroof adjustment regulator, Sunroof button, Alarm horn, Power sunroof control module, Central locking and anti-theft alarm system antenna, Sunroof motor, Fuel filler door unlock motor...............................................................................................................................................................................................................................................................................................................................6750
12. Automatic dimming interior rearview mirror switch, Engine hood contact switch, Automatic dimming interior rearview mirror...............................................................................................................................................................................................................................................................................................................................................................................................6751
13. Light recognition sensor, Automatic high beam assist control module, Automatic dimming interior rearview mirror.........................................................................................................................................................................................................................................................................................................................................................................................................6753
119 -
2.0L gasoline engine , CRZA..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6754
1.
2.0L gasoline engine , CRZA.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6754
2. Battery, Starter, Generator with voltage regulator, Voltage regulator, Terminal 15 power supply relay, Vehicle electrical control module system, Terminal 50 power supply relay, Fuse 1 (on fuse panel A), Fuse 2 (on fuse panel C)......................................................................................................................................................................................................................................................................................6755
3. Engine component power supply relay, Fuse panel B, Fuse 4 (on fuse panel C), Fuse 5 (on fuse panel A), Fuse 27 (on fuse panel C).........................................................................................................................................................................................................................................................................................................................................................................................6756
4. Auxiliary engine coolant pump relay, Fuse panel B, After-run coolant pump................................................................................................................................................................................................................................................................................................................................................................................................................................................6757
5. Motronic engine control module power supply relay, Engine control module, Fuse panel B...................................................................................................................................................................................................................................................................................................................................................................................................................................6758
6. Engine speed sensor, Knock sensor 1, Knock sensor 2, Engine control module...............................................................................................................................................................................................................................................................................................................................................................................................................................................6759
7. Engine control module, Ignition coil 1 with power output stage, Ignition coil 2 with power output stage, Ignition coil 3 with power output stage, Ignition coil 4 with power output stage, Spark plug connectors, Spark plugs............................................................................................................................................................................................................................................................................................6760
8. Accelerator pedal position sensor, Accelerator pedal position sensor 2, Throttle valve control module, Engine control module.............................................................................................................................................................................................................................................................................................................................................................................................6761
9. Camshaft position sensor, Intake air temperature sensor, Engine coolant temperature sensor, Fuel pressure sensor, Intake manifold runner position sensor, Low fuel pressure sensor, Engine control module, Intake flap motor.............................................................................................................................................................................................................................................................................................6762
10. Engine control module, Cylinder 1 fuel injector, Cylinder 2 fuel injector, Cylinder 3 fuel injector, Cylinder 4 fuel injector, Exhaust door valve 1, Leak detection pump................................................................................................................................................................................................................................................................................................................................................6763
11. Mass airflow sensor, Oxygen sensor after catalytic converter, Engine control module, Wastegate bypass regulator valve, EVAP canister purge regulator valve 1, Turbocharger recirculation valve, Fuel pressure regulator valve, Heater for oxygen sensor 1 a ter catalytic converter.....................................................................................................................................................................................................................................6764
12. Charge air pressure sensor, Heated oxygen sensor, Engine coolant temperature sensor on radiator outlet, Engine control module...........................................................................................................................................................................................................................................................................................................................................................................................6765
13. Brake lamp switch, Clutch position sensor, Radiator fan control module, Engine control module, Camshaft adjustment valve 1..............................................................................................................................................................................................................................................................................................................................................................................................6766
14. Oil pressure switch, Charge air pressure gauge, ABS control module, Vehicle electrical control module system, Data bus on board diagnostic interface, Engine control module, Structure borne sound control module, Instrument cluster, Structure-borne sound actuator, Diagnostic connection............................................................................................................................................................................................................................6767
15. Fuel gauge, Outside air temperature sensor, Warning buzzer and tone, Instrument cluster, Oil pressure indicator lamp, Cruise control indicator lamp, Oil level indicator lamp, Malfunction indicator lamp, Low fuel level indicator lamp, Electronic power control malfunction indicator lamp...........................................................................................................................................................................................................................6768
16. Engine hood contact switch, Fuel level sensor, Transfer fuel pump, Fuel pump control module.............................................................................................................................................................................................................................................................................................................................................................................................................................6769
121 -
Standard equipment (NAR).................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6770
1.
Standard equipment (NAR)................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6770
2. Battery, Terminal 15 power supply relay, Fuse 1 (on fuse panel A), Fuse 5 (on fuse panel A), Fuse panel B................................................................................................................................................................................................................................................................................................................................................................................................................6771
3. Fuse panel B, Fuse panel C...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6772
4. Fuse panel C.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6773
5. Load reduction relay, Fuse panel C.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6774
6. Ignition/starter switch, Steering column electronics control module, Ignition switch key lock solenoid...................................................................................................................................................................................................................................................................................................................................................................................................................6775
7. Signal horn activation, Steering column electronics control module, Driver airbag igniter................................................................................................................................................................................................................................................................................................................................................................................................................................6776
8. Turn signal switch, Headlamp dimmer/flasher switch, Windshield wiper intermittent mode switch, Rear window wiper switch, Windshield wiper intermittent regulator, Windshield and headlamp washer pump switch, Cruise control switch, Multifunction indicator selection switch, Multifunction indicator memory switch, Cruise control -SET- button, Steering column electronics control module............................................................................................................................6777
9. Left front fog lamp bulb, Left cornering lamp bulb, Left daytime running lamp bulb, Left position lamp bulb, Left front turn signal bulb, Left low beam headlamp bulb, Left high beam headlamp bulb, Left front side marker lamp bulb....................................................................................................................................................................................................................................................................................6778
10. Instrument panel and switch illumination dimmer switch, Back-up lamp switch, Engine hood contact switch, High tone horn, Low tone horn, Dual tone horn relay............................................................................................................................................................................................................................................................................................................................................................6779
11. Right front fog lamp bulb, Right cornering lamp bulb, Right position lamp bulb, Right front turn signal bulb, Right low beam headlamp bulb, Right high beam headlamp bulb, Right front side marker lamp bulb............................................................................................................................................................................................................................................................................................................6780
12. Light switch, Fog lamp switch, Fog lamp indicator lamp, Automatic light control indicator lamp..........................................................................................................................................................................................................................................................................................................................................................................................................................6781
13. Right tail lamp bulb, Left tail lamp bulb, Left rear turn signal bulb, Right rear turn signal bulb, Left back-up lamp bulb, Right back-up lamp bulb, Left brake/tail lamp bulb, Right brake/tail lamp bulb..............................................................................................................................................................................................................................................................................................................6782
14. Rear window defogger relay, Driver exterior rearview mirror turn signal bulb, Front passenger exterior rearview mirror turn signal bulb, High-mounted brake lamp bulb, Left license plate lamp, Right license plate lamp, Rear window defogger..........................................................................................................................................................................................................................................................................6783
15. Emergency flasher button, Left washer nozzle heater, Right washer nozzle heater.........................................................................................................................................................................................................................................................................................................................................................................................................................................6784
16. Rain/light recognition sensor, Wiper motor control module, Rear window wiper motor, Windshield and rear window washer pump, Driver windshield wiper motor...............................................................................................................................................................................................................................................................................................................................................................6785
17. Glove compartment lamp switch, Brake lamp switch, Luggage compartment lamp, Glove compartment lamp......................................................................................................................................................................................................................................................................................................................................................................................................................6786
18. Front interior lamp, Left rear reading lamp, Right rear reading lamp, Front passenger reading lamp, Driver reading lamp, Rear interior lamp.............................................................................................................................................................................................................................................................................................................................................................................6787
19. Driver vanity mirror lamp contact switch, Front passenger vanity mirror lamp contact switch, Blocking diode, Cigarette lighter illumination bulb, Cigarette lighter, 12 V socket, Left footwell lamp, Right footwell lamp, Front passenger vanity mirror lamp, Driver vanity mirror lamp................................................................................................................................................................................................................................6788
20. Fresh air blower switch, Heater/heat output switch, Fresh air blower series resistor with fuse, Fresh air blower, Recirculation door motor..............................................................................................................................................................................................................................................................................................................................................................................6789
21. Data bus on board diagnostic interface, Diagnostic connection...........................................................................................................................................................................................................................................................................................................................................................................................................................................................6790
22. Anti-theft immobilizer reader coil, Brake fluid level warning switch, Warning buzzer and tone, Instrument cluster control module, Cruise control indicator lamp, Anti-theft immobilizer indicator lamp, Door ajar indicator lamp, Lamp failure indicator lamp, Hood -open- indicator lamp...............................................................................................................................................................................................................................6791
23. Parking brake indicator lamp switch, Tachometer, Speedometer, Windshield washer fluid level sensor, Left front brake pad wear sensor, Instrument cluster control module, High beam indicator lamp, Windshield washer fluid level indicator lamp.........................................................................................................................................................................................................................................................................6792
24. Fuel gauge, Engine coolant temperature gauge, Outside air temperature sensor, Engine coolant level sensor, Multifunction indicator, Instrument cluster control module, Position lamp indicator lamp, Rear fog lamp indicator lamp, Engine electronics indicator lamp, Odometer display..................................................................................................................................................................................................................................6793
134 -
2.0L gasoline engine , CBFA..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6794
1.
2.0L gasoline engine , CBFA.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6794
2. Battery, Starter, Generator, Fuse 1 (on fuse panel A)....................................................................................................................................................................................................................................................................................................................................................................................................................................................................6795
3. Terminal 50 power supply relay, Starter relay 1, Starter relay 2.........................................................................................................................................................................................................................................................................................................................................................................................................................................................6796
4. Terminal 15 power supply relay, Fuse 5 (on fuse panel A), Fuse panel B...................................................................................................................................................................................................................................................................................................................................................................................................................................................6797
5. Fuel level sensor, Transfer fuel pump, Secondary air injection pump relay, Fuel pump control module, Fuse panel B, Secondary air injection pump motor....................................................................................................................................................................................................................................................................................................................................................................6798
6. Motronic engine control module power supply relay, Fuse panel B..........................................................................................................................................................................................................................................................................................................................................................................................................................................................6799
7. Steering column electronics control module, Engine control module........................................................................................................................................................................................................................................................................................................................................................................................................................................................6800
8. Engine coolant temperature sensor, Coolant circulation pump relay, Engine control module, After-run coolant pump.........................................................................................................................................................................................................................................................................................................................................................................................................6801
9. Engine control module, Ignition coil 1 with power output stage, Ignition coil 2 with power output stage, Ignition coil 3 with power output stage, Ignition coil 4 with power output stage, Spark plugs...................................................................................................................................................................................................................................................................................................................6802
10. Engine speed sensor, Throttle valve control module, Engine control module, Fuel pressure regulator valve................................................................................................................................................................................................................................................................................................................................................................................................................6803
11. Charge air pressure sensor, Camshaft position sensor, Knock sensor 1, Fuel pressure sensor, Intake manifold runner position sensor, Engine control module...............................................................................................................................................................................................................................................................................................................................................................6804
12. Intake air temperature sensor, Intake manifold runner position sensor, Secondary air injection sensor 1, Engine control module, Cylinder 1 fuel injector, Cylinder 2 fuel injector, Cylinder 3 fuel injector, Cylinder 4 fuel injector..................................................................................................................................................................................................................................................................................6805
13. Accelerator pedal position sensor, Accelerator pedal position sensor 2, Engine control module, Wastegate bypass regulator valve, EVAP canister purge regulator valve 1, Turbocharger recirculation valve................................................................................................................................................................................................................................................................................................................6806
14. Map controlled engine cooling thermostat, Mass airflow sensor, Engine coolant temperature sensor on radiator outlet, Engine control module, Secondary air injection solenoid valve, Camshaft adjustment valve 1, Intake manifold runner control valve...................................................................................................................................................................................................................................................................6807
15. Heated oxygen sensor, Radiator identification sensor, Engine control module, Leak detection pump........................................................................................................................................................................................................................................................................................................................................................................................................................6808
16. Brake lamp switch, Heated oxygen sensor 2, Oxygen sensor after catalytic converter, Engine control module...............................................................................................................................................................................................................................................................................................................................................................................................................6809
17. Clutch position sensor, Engine control module...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6810
18. ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6811
19. Multifunction indicator, Data bus on board diagnostic interface.........................................................................................................................................................................................................................................................................................................................................................................................................................................................6812
20. Oil pressure switch, Fuel gauge, Engine coolant temperature gauge, Engine coolant level sensor, Malfunction indicator lamp..............................................................................................................................................................................................................................................................................................................................................................................................6813
136 -
2.5L gasoline engine , CBTA, CBUA........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6814
1.
2.5L gasoline engine , CBTA, CBUA.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6814
2. Battery, Starter, Generator, Fuse 1 (on fuse panel A), Fuse 2 (on fuse panel C), Fuse 5 (on fuse panel A), Fuse 27 (on fuse panel C).....................................................................................................................................................................................................................................................................................................................................................................................6815
3. Fuel pump relay, Terminal 15 power supply relay, Terminal 50 power supply relay, Fuse panel B............................................................................................................................................................................................................................................................................................................................................................................................................................6816
4. Secondary air injection pump relay, Fuse panel B, Secondary air injection pump motor.....................................................................................................................................................................................................................................................................................................................................................................................................................................6817
5. Motronic engine control module power supply relay, Engine control module, Fuse panel B...................................................................................................................................................................................................................................................................................................................................................................................................................................6818
6. Engine control module, Ignition coil 1 with power output stage, Ignition coil 2 with power output stage, Ignition coil 3 with power output stage, Ignition coil 4 with power output stage, Spark plugs...................................................................................................................................................................................................................................................................................................................6819
7. Engine coolant temperature sensor, Engine coolant temperature sensor on radiator outlet, Throttle valve control module, Engine control module, Ignition coil 5 with power output stage...................................................................................................................................................................................................................................................................................................................................6820
8. Camshaft position sensor, Intake air temperature sensor, Knock sensor 1, Knock sensor 2, Manifold absolute pressure sensor, Secondary air injection sensor 1, Engine control module......................................................................................................................................................................................................................................................................................................................................6821
9. Engine speed sensor, Camshaft position sensor, Engine control module, Cylinder 1 fuel injector, Cylinder 2 fuel injector, Cylinder 3 fuel injector, Cylinder 4 fuel injector, Cylinder 5 fuel injector, Leak detection pump..............................................................................................................................................................................................................................................................................................6822
10. Accelerator pedal position sensor, Accelerator pedal position sensor 2, Engine control module, EVAP canister purge regulator valve 1, Secondary air injection solenoid valve, Camshaft adjustment valve 1...............................................................................................................................................................................................................................................................................................................6823
11. Heated oxygen sensor, Oxygen sensor after catalytic converter, Center oxygen sensor for bank 1 catalytic converter, Engine control module...............................................................................................................................................................................................................................................................................................................................................................................6824
12. Brake lamp switch, Center oxygen sensor for bank 1 catalytic converter, Clutch position sensor, Engine control module...................................................................................................................................................................................................................................................................................................................................................................................................6825
13. Vehicle electrical control module system, Engine control module.........................................................................................................................................................................................................................................................................................................................................................................................................................................................6826
14. Multifunction indicator, Instrument cluster control module, Vehicle electrical control module system, Data bus on board diagnostic interface............................................................................................................................................................................................................................................................................................................................................................................6827
15. Oil pressure switch, Fuel level sensor, Fuel gauge, Engine coolant temperature gauge, Transfer fuel pump, Engine coolant level sensor, Instrument cluster control module................................................................................................................................................................................................................................................................................................................................................6828
137 -
Auxiliary heater (PTC), gasoline engine , (7E6)..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6829
1.
Auxiliary heater (PTC), gasoline engine , (7E6).........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6829
2. Terminal 30 power supply relay, Low heat output relay, High heat output relay, Engine control module, Fuse 1 (on fuse panel A), Fuse 4 (on fuse panel A), Fuse 6 (on fuse panel A), Fuse panel B, Auxiliary heater heating element.......................................................................................................................................................................................................................................................................................6830
3. Fresh air blower switch, A/C control module, Fresh air blower series resistor with fuse, Fresh air blower................................................................................................................................................................................................................................................................................................................................................................................................................6831
138 -
Washer system, headlamps , (8X1).........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6832
1.
Washer system, headlamps , (8X1)........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6832
2. Headlamp washer relay, Headlamp washer pump..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6833
3. Windshield wiper intermittent mode switch, Rear window wiper switch, Windshield and headlamp washer pump switch, Windshield washer fluid level sensor, Instrument cluster control module, Steering column electronics control module, Data bus on board diag
ostic interface, Windshield washer fluid level indicator lamp...............................................................................................................................................................................................6834
139 -
Compass , (QR1)..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6835
1.
Compass , (QR1).........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6835
2. Terminal 15 power supply relay, Fuse panel B, Fuse 2 (on fuse panel C), Fuse 5 (on fuse panel A), Fuse 13 (on fuse panel C)..............................................................................................................................................................................................................................................................................................................................................................................................6836
3. Compass magnetic field sensor, Voltage stabilizer, Data bus on board diagnostic interface, Fuse 48 (on fuse panel C).....................................................................................................................................................................................................................................................................................................................................................................................................6837
145 -
Headlamps HID with range control , (8G0).................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6838
1.
Headlamps HID with range control , (8G0)................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6838
2. Terminal 15 power supply relay, Vehicle electrical control module system, Fuse panel B, Fuse panel C.....................................................................................................................................................................................................................................................................................................................................................................................................................6839
3. Left HID headlamp control module, Vehicle electrical control module system, Left HID headlamp bulb, Left front fog lamp bulb, Left cornering lamp bulb, Left daytime running lamp and position lamp LED module, Left front turn signal bulb..............................................................................................................................................................................................................................................................................6840
4. Vehicle electrical control module system, Data bus on board diagnostic interface, Left headlamp power output module, Cornering lamp and headlamp range control module, Left headlamp beam adjustment motor, Left low beam headlamp reflector motor.......................................................................................................................................................................................................................................................................6841
5. Left rear level control system sensor, Vehicle electrical control module system, Right headlamp power output module, Cornering lamp and headlamp range control module, Right headlamp beam adjustment motor, Right low beam headlamp reflector motor.....................................................................................................................................................................................................................................................................6842
6. Right HID headlamp control module, Vehicle electrical control module system, Right HID headlamp bulb, Right front fog lamp bulb, Right cornering lamp bulb, Right daytime running lamp and position lamp LED module, Right front turn signal bulb........................................................................................................................................................................................................................................................................6843
7. Vehicle electrical control module system, Lighting control illumination bulb.............................................................................................................................................................................................................................................................................................................................................................................................................................................6844
148 -
2.0L gasoline engine , CCTA..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6845
1.
2.0L gasoline engine , CCTA.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6845
2. Battery, Starter, Generator, Terminal 50 power supply relay, Fuse 1 (on fuse panel A)....................................................................................................................................................................................................................................................................................................................................................................................................................................6846
3. Terminal 15 power supply relay, Fuse 5 (on fuse panel A), Fuse panel B...................................................................................................................................................................................................................................................................................................................................................................................................................................................6847
4. Fuel level sensor, Transfer fuel pump, Fuel pump control module, Engine component power supply relay, Fuse panel B.......................................................................................................................................................................................................................................................................................................................................................................................................6848
5. Motronic engine control module power supply relay, Fuse panel B..........................................................................................................................................................................................................................................................................................................................................................................................................................................................6849
6. Steering column electronics control module, Engine control module........................................................................................................................................................................................................................................................................................................................................................................................................................................................6850
7. Mass airflow sensor, Engine coolant temperature sensor on radiator outlet, Coolant circulation pump relay, Throttle valve control module, Engine control module, After-run coolant pump..................................................................................................................................................................................................................................................................................................................................6851
8. Engine control module, Ignition coil 1 with power output stage, Ignition coil 2 with power output stage, Ignition coil 3 with power output stage, Ignition coil 4 with power output stage, Spark plugs...................................................................................................................................................................................................................................................................................................................6852
9. Engine speed sensor, Charge air pressure sensor, Camshaft position sensor, Knock sensor 1, Fuel pressure sensor, Engine control module...................................................................................................................................................................................................................................................................................................................................................................................6853
10. Intake air temperature sensor, Engine coolant temperature sensor, Intake manifold runner position sensor, Engine control module, Cylinder 1 fuel injector, Cylinder 2 fuel injector, Fuel pressure regulator valve......................................................................................................................................................................................................................................................................................................6854
11. Accelerator pedal position sensor, Accelerator pedal position sensor 2, Engine control module, Cylinder 3 fuel injector, Cylinder 4 fuel injector, EVAP canister purge regulator valve 1, Turbocharger recirculation valve..............................................................................................................................................................................................................................................................................................6855
12. Oxygen sensor after catalytic converter, Engine control module, Wastegate bypass regulator valve, Camshaft adjustment valve 1, Intake manifold runner control valve, Oil pressure regulation valve......................................................................................................................................................................................................................................................................................................................6856
13. Brake lamp switch, Heated oxygen sensor, Clutch position sensor, Engine control module, Leak detection pump.............................................................................................................................................................................................................................................................................................................................................................................................................6857
14. Vehicle electrical control module system, Engine control module.........................................................................................................................................................................................................................................................................................................................................................................................................................................................6858
15. Vehicle electrical control module system, Data bus on board diagnostic interface........................................................................................................................................................................................................................................................................................................................................................................................................................................6859
16. Oil pressure switch, Reduced oil pressure switch, Fuel gauge, Engine coolant temperature gauge, Engine coolant level sensor, Multifunction indicator, Instrument cluster control module, Malfunction indicator lamp, Electronic power control malfunction i
dicator lamp................................................................................................................................................................................................................................................6860
149 -
Access/start authorization (USA and Canada)..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6861
1.
Access/start authorization (USA and Canada).............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6861
2. Vehicle electrical control module system, Fuse 5 (on fuse panel A), Fuse panel B, Fuse panel C...........................................................................................................................................................................................................................................................................................................................................................................................................................6862
3. Vehicle electrical control module system, Steering column electronics control module, Electronic steering column lock control module, Steering column lock actuator......................................................................................................................................................................................................................................................................................................................................................6863
4. Anti-theft immobilizer reader coil, Start system button, Access/start authorization control module, Electronic steering column lock control module, Access/start system antenna 1 in vehicle interior....................................................................................................................................................................................................................................................................................................................6864
5. Driver exterior door handle touch sensor, Front passenger exterior door handle touch sensor, Access/start authorization control module, Driver access/start system antenna, Front passenger access/start system antenna, Access/start system antenna in rear bumper, Access/start system antenna in luggage compartment..................................................................................................................................................................................................6865
6. Access/start authorization control module, Data bus on board diagnostic interface........................................................................................................................................................................................................................................................................................................................................................................................................................................6866
150 -
Seat backrest adjustment (NAR)...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6867
1.
Seat backrest adjustment (NAR)..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6867
2. Driver seat adjustment control head, Front passenger seat adjustment control head, Driver and front passenger seat circuit breaker, Driver backrest adjustment motor, Front passenger backrest adjustment motor..........................................................................................................................................................................................................................................................................................................6868
152 -
Headlamps Bixenon HID with range control, cornering lamp, LED daytime running lamps , (A9R)..............................................................................................................................................................................................................................................................................................................................................................................................................................6869
1.
Headlamps Bixenon HID with range control, cornering lamp, LED daytime running lamps , (A9R).............................................................................................................................................................................................................................................................................................................................................................................................................................6869
2. Battery, Terminal 15 power supply relay, Vehicle electrical control module system, Fuse panel B, Fuse panel C, Fuse 1 (on fuse panel C)..................................................................................................................................................................................................................................................................................................................................................................................6870
3. Vehicle electrical control module system, Left daytime running lamp and position lamp LED module, Left front headlamp....................................................................................................................................................................................................................................................................................................................................................................................................6871
4. Left rear level control system sensor, Headlamp range control module, Left front headlamp, Right front headlamp..........................................................................................................................................................................................................................................................................................................................................................................................................6872
5. Vehicle electrical control module system, Right daytime running lamp and position lamp LED module, Right front headlamp..................................................................................................................................................................................................................................................................................................................................................................................................6873
6. Turn signal switch, Headlamp dimmer/flasher switch, Instrument cluster control module, Vehicle electrical control module system, Steering column electronics control module, Data bus on board diagnostic interface......................................................................................................................................................................................................................................................................................................6874
7. Light switch, Instrument panel and switch illumination dimmer switch, Vehicle electrical control module system, Lighting control illumination bulb.......................................................................................................................................................................................................................................................................................................................................................................6875
153 -
E-box High fuse assignment...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6876
1.
E-box High fuse assignment..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6876
2. Battery, Starter, Generator..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6877
3. Fuse panel B, Fuse 1 (on fuse panel B), Fuse 2 (on fuse panel B), Fuse 4 (on fuse panel B), Fuse 5 (on fuse panel B).....................................................................................................................................................................................................................................................................................................................................................................................................6878
4. Fuse panel B, Fuse 31 (on fuse panel B), Fuse 47 (on fuse panel B), Fuse 48 (on fuse panel B), Fuse 52 (on fuse panel B), Fuse 53 (on fuse panel B)......................................................................................................................................................................................................................................................................................................................................................................6879
5. Motronic engine control module power supply relay, Auxiliary engine coolant pump relay, Fuse panel B, Fuse 15 (on fuse panel B), Fuse 28 (on fuse panel B), Fuse 29 (on fuse panel B)....................................................................................................................................................................................................................................................................................................................................6880
6. Fuse panel B, Fuse 27 (on fuse panel B), Fuse 38 (on fuse panel B), Fuse 39 (on fuse panel B), Fuse 40 (on fuse panel B), Fuse 42 (on fuse panel B)......................................................................................................................................................................................................................................................................................................................................................................6881
7. Fuse panel B, Fuse 17 (on fuse panel B), Fuse 18 (on fuse panel B), Fuse 23 (on fuse panel B), Fuse 24 (on fuse panel B).................................................................................................................................................................................................................................................................................................................................................................................................6882
8. Radio/navigation display unit control module, Engine component power supply relay, Fuse panel B, Fuse 19 (on fuse panel B), Fuse 20 (on fuse panel B), Fuse 49 (on fuse panel B).........................................................................................................................................................................................................................................................................................................................................6883
9. Fuse panel B, Fuse 7 (on fuse panel B), Fuse 9 (on fuse panel B), Fuse 11 (on fuse panel B), Fuse 12 (on fuse panel B), Oxygen sensor heater, Heater for oxygen sensor 1 after catalytic converter.......................................................................................................................................................................................................................................................................................................................6884
802 - - Component Locations: Fuses - 3..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6885
1. Fuses....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6885
1.1 Fuses overview......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6885
1.2 Fuse (SA) on E-Box Low, from October 2008...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6886
1.3 Fuse (SA) on E-Box High, from November 2009.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6887
1.4 Fuse (SA) on E-Box Low, Golf Blue-E-Motion..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6889
1.5 Fuse (SB) on E-box Low, from October 2008...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6891
1.6 Fuse (SB) on E-box Low, from May 2009...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6895
1.7 Fuse (SB) on E-box Low, from November 2009..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6899
1.8 Fuse (SB) on E-box Low, from May 2010...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6904
1.9 Fuse (SB) on E-box Low, from May 2011...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6909
1.10 Fuse (SB) on E-Box High, from November 2009........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6915
1.11 Fuse (SB) on E-box Low, Golf Blue-E-Motion.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6918
1.12 Fuse (SF) on High voltage charge network distributor SX4, Golf Blue-E-Motion.......................................................................................................................................................................................................................................................................................................................................................................................................................................6921
1.12.1 Fuse (SF) on High voltage charge network distributor SX4, Golf Blue-E-Motion.................................................................................................................................................................................................................................................................................................................................................................................................................................6923
1.13 Fuses (SD) location in the connection-and junction box 1 SX1, GolfBlue-E-Motion....................................................................................................................................................................................................................................................................................................................................................................................................................................6925
1.13.1 Fuse (SD), Golf-Blue-E-Motion................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6926
1.14 Fuse (SC), from October 2008.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6928
1.15 Fuse (SC), from May 2009...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6934
1.16 Fuse (SC), from November 2009......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6941
1.17 Fuse (SC), from May 2010...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6949
1.18 Fuse (SC), from May 2011...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6956
1.19 Fuse (SC), Golf Blue-E-Motion......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6962
1.20 Circuit breaker, through May 2010..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6966
1.21 Circuit breaker, from May 2010.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6968
805 - - Component Locations: Relays - 3.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6969
1. Relays...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6969
1.1 Relays Carrier Overview.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6969
1.2 Relay on E-Box Low..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6970
1.3 Relay on E-Box Low, Golf Blue-E-Motion..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6971
1.4 Relay on E-Box High.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6972
1.5 Relay on Auxiliary Relay Carrier....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6973
1.5.1 Relay on Auxiliary Relay Carrier, for fuel engines............................................................................................................................................................................................................................................................................................................................................................................................................................................................6973
1.5.2 Relay on Auxiliary Relay Carrier, Golf Blue-E-Motion..........................................................................................................................................................................................................................................................................................................................................................................................................................................................6974
1.6 High voltage charge network distributor -SX4-.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6975
1.6.1 High voltage charge network distributor -SX4- location........................................................................................................................................................................................................................................................................................................................................................................................................................................................6975
1.6.2 Relay on high voltage charge network distributor -SX4-........................................................................................................................................................................................................................................................................................................................................................................................................................................................6977
1.7 Relay above J519 module, through October 2009.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6978
1.8 Relay above J519 module, from November 2009.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6979
1.9 Relay above J519 module, from November 2011.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6980
1.10 Relay above J519 module, Golf Blue-E-Motion........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6981
1.11 Relay below J519 module, through October 2009......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6982
1.12 Relay below J519 module, from November 2009........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6984
1.13 Relays below J519 module , from November 2011......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6985
1.14 Relay below J519 module, Golf Blue-E-Motion........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6986
851 - - Component Locations: Vehicle Front - 3..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6987
1. Component Locations: Vehicle Front.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6987
1.1 Engine..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6987
1.1.1 2.0L TDI - CJAA Front View....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6987
1.1.2 2.0L TDI - CJAA Rear View.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6989
1.1.3 2.0L TDI - CJAA Left View.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6990
1.1.4 2.0L TFSI - CCTA/CBFA/CRZA Top View...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6991
1.1.5 2.0L TFSI - CCTA/CBFA/CRZA Front View.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6992
1.1.6 2.0L TFSI - CCTA/CBFA/CRZA Right View.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................6993
1.1.7 2.5L SRE - CBTA/CBUA Top View.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6994
1.1.8 2.5L SRE - CBTA/CBUA Front View...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6995
1.1.9 2.5L SRE - CBTA/CBUA Rear View................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6996
1.2 Engine Compartment..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6996
1.2.1 Engine compartment, passenger side............................................................................................................................................................................................................................................................................................................................................................................................................................................................................6997
1.2.2 Engine compartment, driver side, Part I.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6998
1.2.3 Engine compartment, driver side, Part II......................................................................................................................................................................................................................................................................................................................................................................................................................................................................6999
1.3 Transmission........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7000
1.3.1 Manual Transmission - 02Q / 0A4...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7000
1.3.2 DSG Transmission - 02E........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7002
1.3.3 6-speed Automatic Transmission - 09G..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7003
1.4 Front Bumper........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7004
852 - - Component Locations: Vehicle Rear - 3...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7005
1. Component Locations:
Vehicle Rear........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7005
1.1 Luggage Compartment.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7005
1.1.1 Left Side.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7005
1.1.2 Right Side....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7007
1.2 Trunk Lid...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7008
1.3 Bumper..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7009
853 - - Component Locations: Vehicle Cabin - 3..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7010
1. Component Locations:
Vehicle Cabin.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7010
1.1 Instrumentation.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7010
1.1.1 Instrument Panel - Center.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7010
1.1.2 Instrument Panel - Right......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7012
1.1.3 Instrument Panel - Left.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7013
1.1.4 Steering, Part I..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7014
1.1.5 Steering, Part II.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7015
1.2 HVAC................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7015
1.2.1 Climatic, Part I..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7016
1.2.2 Climatic, Part II.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7017
1.2.3 Climatronic, Part I...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7018
1.2.4 Climatronic, Part II..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7019
1.3 A & B Pillar Area - Left............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7020
1.4 A & B Pillar Area - Right...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7021
1.5 C Pillar Area - Left................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7022
1.6 C Pillar Area - Right...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7023
1.7 Floor...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7024
1.8 Door - Left Front...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7025
1.9 Door - Right Front..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7026
1.10 Door - Left Rear...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7027
1.11 Door - Right Rear..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7028
1.12 Roof...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7028
1.12.1 Roof, front without sunroof..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7029
1.12.2 Roof, front with sunroof.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7030
1.12.3 Roof, rear...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7031
854 - - Component Locations: Vehicle Under Body - 3.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7032
1. Component Locations: Vehicle Under Body
...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7032
1.1 All Wheel Drive.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7032
1.2 Exhaust.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7033
1.2.1 2.0L TDI CJAA, Part I.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7033
1.2.2 2.0L TDI CJAA, Part II........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7035
1.2.3 2.0L TFSI, CCTA/CBFA/CRZA.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7036
1.2.4 2.5L SRE, CBTA/CBUA...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7037
877 - Wiring - General Information - 3..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7038
1. Understanding Wiring Diagrams Terminology and Symbols....................................................................................................................................................................................................................................................................................................................................................................................................................................................................7038
1.1 Capacitor...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7038
1.2 Connector...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7038
1.3 Component Code Prefixes.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7039
1.4 DIN Standard 72 552.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7040
1.5 Diode...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7046
1.6 Fuse................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7047
1.7 LED (Light-emitting Diode)..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7048
1.8 Module..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7048
1.9 Motor...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7049
1.10 Potentiometer or Rheostat..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7050
1.11 Relay..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7051
1.12 Resistor...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7052
1.13 Sensors............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7053
1.14 Solenoid...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7055
1.15 Switch.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7055
1.16 Solenoid...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7058
1.17 Symbols............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7058
1.18 Transistor.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7074
1.19 Wire...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7075
1.19.2 Wire color...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7076
1.19.3 Wire Gauge...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7077
1.19.4 Wire Layout..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7077
1.19.5 Wire Connection..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7078
880 - - Connector Views: A/C Systems - 3........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7081
1. A/C Systems - Connector Views............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7081
1.1 Fresh air blower -V2-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7081
1.2 High pressure sensor -G65-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7081
1.3 A/C compressor regulator valve -N280-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7082
1.4 A/C control module -J301-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7082
1.5 Air distribution door motor -V428-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7084
1.6 Recirculation door motor -V113-.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7085
1.7 Temperature regulator door motor -V68-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7085
1.8 Evaporator vent temperature sensor -G263-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7086
1.9 Footwell vent temperature sensor -G192-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7086
1.10 Center vent temperature sensor -G191-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7087
1.11 Fresh air blower series resistor with fuse -N24-...................................................................................................................................................................................................................................................................................................................................................................................................................................................................7087
1.12 Fresh air blower control module -J126-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7088
1.13 Air quality sensor -G238-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7088
1.14 Climatronic control module -J255-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7089
1.15 Sunlight photo sensor -G107-.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7091
1.16 Left temperature door motor -V158-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7092
1.17 Right temperature door motor -V159-................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7092
1.18 Fresh air/recirculating air/back pressure door motor -V425-........................................................................................................................................................................................................................................................................................................................................................................................................................................................7093
1.19 Left footwell vent temperature sensor -G261-.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................7094
1.20 Right footwell vent temperature sensor -G262-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................7094
1.21 Left vent temperature sensor -G150-................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7095
1.22 Right vent temperature sensor -G151-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7095
1.23 Evaporator temperature sensor -G308-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7096
1.24 Front air distribution door motor -V426-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7096
1.25 Defroster door motor -V107-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7097
881 - - Connector Views: ABS - 3................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7098
1. ABS Connector Views......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7098
1.1 ABS control module -J104-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7098
1.2 Vacuum sensor -G608-................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7100
1.3 Right rear ABS wheel speed sensor -G44-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7101
1.4 Right front ABS wheel speed sensor -G45-............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7101
1.5 Left rear ABS wheel speed sensor -G46-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7102
1.6 Left front ABS wheel speed sensor -G47-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7102
883 - - Connector Views: Airbag - 3.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7103
1. Airbag Connector Views...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7103
1.1 Front passenger airbag igniter 1 -N131- and Front passenger airbag igniter 2 -N132-.................................................................................................................................................................................................................................................................................................................................................................................................................................7104
1.2 Driver head curtain airbag igniter -N251-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7104
1.3 Front passenger head curtain airbag igniter -N252-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................7105
1.4 Left rear thorax airbag igniter -N201-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7107
1.5 Right rear thorax airbag igniter -N202-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7107
1.6 Front passenger airbag -disabled- indicator lamp -K145-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................7108
1.7 Left rear thorax airbag crash sensor -G256-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7108
1.8 Right rear thorax airbag crash sensor -G257-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7109
1.9 Driver front airbag crash sensor -G283-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7109
1.10 Front passenger front airbag crash sensor -G284-...................................................................................................................................................................................................................................................................................................................................................................................................................................................................7110
1.11 Driver seat belt switch -E24-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7110
1.12 Passenger occupant detection system control module -J706-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................7111
1.13 Front passenger seat belt switch -E25-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7112
1.14 Driver thorax airbag igniter -N199-................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7112
1.15 Front passenger thorax airbag igniter -N200-.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................7113
1.16 Driver seat position sensor -G553-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7113
1.17 Driver side airbag crash sensor -G179-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7114
1.18 Front passenger side airbag crash sensor -G180-....................................................................................................................................................................................................................................................................................................................................................................................................................................................................7114
1.19 Left rear seat belt tensioner igniter -N196-.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................7115
1.20 Right rear seat belt tensioner igniter -N197-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................7115
1.21 Front passenger seat belt tensioner igniter 1 -N154-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................7116
1.22 Driver seat belt tensioner igniter 1 -N153-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7116
1.23 Airbag control module -J234-.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7117
885 - - Connector Views: Engine - 3.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7119
1. Engine Connector Views...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7119
1.1 EGR vacuum regulator solenoid valve -N18-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7121
1.2 Valve 2 for EGR -N213-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7121
1.3 Intake flap motor -V157-............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7122
1.4 EGR temperature sensor -G98-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7123
1.5 Exhaust gas temperature sensor 4 -G648-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7124
1.6 Exhaust gas temperature sensor 1 -G235-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7124
1.7 Brake lamp switch -F-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7125
1.8 Exhaust pressure sensor 1 -G450-....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7125
1.9 Differential pressure sensor -G505-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7126
1.10 Charge air pressure sensor -G31-...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7126
1.11 Fuel pressure sensor -G247-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7129
1.12 Engine speed sensor -G28-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7129
1.13 Wastegate bypass regulator valve -N75-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7130
1.14 Cylinder 1 fuel injector -N30-.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7131
1.15 Accelerator pedal module -GX2-.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7132
1.16 Automatic glow time control module -J179-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7133
1.17 Mass airflow sensor -G70-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7133
1.18 Positive crankcase ventilation heating element -N79-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................7135
1.19 Fuel pressure regulator valve -N276-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7135
1.20 Camshaft position sensor -G40-.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7136
1.21 Heated oxygen sensor -G39-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7138
1.22 Oxygen sensor after three way catalytic converter -G130-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................7138
1.23 Oxygen sensor in bank 1 center three way catalyticconverter -G465-.................................................................................................................................................................................................................................................................................................................................................................................................................................................7139
1.24 Heated oxygen sensor 2 -G108-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7140
1.25 Charge pressure actuator position sensor -G581-....................................................................................................................................................................................................................................................................................................................................................................................................................................................................7140
1.26 Fuel metering valve -N290-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7141
1.27 Throttle valve control module -J338-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7141
1.28 Exhaust door control unit -J883-...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7143
1.29 Engine coolant temperature sensor on radiator -G83-................................................................................................................................................................................................................................................................................................................................................................................................................................................................7144
1.30 Engine coolant temperature sensor -G62-............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7144
1.31 Fuel temperature sensor -G81-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7145
1.32 Exhaust gas temperature sensor 3 -G495-............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7145
1.33 Exhaust gas temperature sensor 2 -G448-............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7146
1.34 Clutch position sensor -G476-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7146
1.35 EVAP canister purge regulator valve 1 -N80-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7147
1.36 Intake manifold runner control valve -N316-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7148
1.37 Knock sensor 1 -G61-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7148
1.38 Knock sensor 2 -G66-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7149
1.39 Leak detection pump -V144-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7149
1.40 Camshaft adjustment valve 1 -N205-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7150
1.41 Turbocharger recirculation valve -N249-............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7151
1.42 Secondary air injection solenoid valve -N112-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................7152
1.43 Radiator identification sensor -G611-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7152
1.44 Secondary air injection sensor 1 -G609-............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7153
1.45 ...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7154
1.46 Ignition coil 1 with power output stage -N70-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................7154
1.47 Reduced oil pressure switch -F378-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7155
1.48 Oil pressure regulation valve -N428-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7155
887 - - Connector Views: Parking Aid - 3........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7156
1. Parking Aid Connector Views..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7156
1.1 Rear parking aid warning buzzer -H15-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7156
1.2 Front parking aid warning buzzer -H22-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7157
1.3 Right front parking aid sensor -G252-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7157
1.4 Right front center parking aid sensor -G253-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7158
1.5 Left front center parking aid sensor -G254-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7158
1.6 Left front parking aid sensor -G255-................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7159
1.7 Left front parallel parking assistance sensor -G568-................................................................................................................................................................................................................................................................................................................................................................................................................................................................7159
1.8 Right front parallel parking assistance sensor -G569-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................7160
1.9 Left rear parking aid sensor -G203-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7160
1.10 Left rear center parking aid sensor -G204-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7161
1.11 Right rear center parking aid sensor -G205-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7162
1.12 Right rear parking aid sensor -G206-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7162
1.13 Parking aid button -E266-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7163
1.14 Parking aid control module -J446-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7163
889 - - Connector Views: Suspension - 3.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7166
1. Suspension Connector Views...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7166
1.1 Damping adjustment button -E387-....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7166
1.2 Left front damping adjustment valve -N336-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7167
1.3 Right front damping adjustment valve -N337-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7167
1.4 Left rear damping adjustment valve -N338-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7168
1.5 Right rear damping adjustment valve -N339-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7168
1.6 Right front level control sensor -G289-.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7169
1.7 Left front level control system sensor -G78-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7169
1.8 Left rear level control system sensor -G76-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7170
1.9 Front body acceleration sensors -G341-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7170
1.10 Right front body acceleration sensor -G342-........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7171
1.11 Rear body acceleration sensor -G343-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7171
1.12 Electronic damping control module -J250-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7172
890 - - Connector Views: Transmission - 3.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7174
1. Transmission Systems Connector Views.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7174
1.1 Selector lever -E313-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7174
1.2 Transmission fluid temperature sensor -G93-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7176
1.3 Multifunction transmission range switch -F125-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................7177
1.4 Transmission valve body solenoids...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7178
1.5 Transmission control module -J217-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7178
1.6 DSG transmission Mechatronic -J743-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7180
1.7 Transmission input speed sensor -G182-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7181
895 - - Connector Views: Comfort - 3............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7182
1. Comfort Connector Views..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7182
1.1 Driver seat height adjustment motor -V138-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7183
1.2 Driver seat forward/back adjustment motor -V28-.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................7183
1.3 Seat angle adjustment motor -V231-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7184
1.4 Driver backrest adjustment motor -V45-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7184
1.5 Driver seat lumbar support adjustment switch -E176-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................7185
1.6 Driver seat lumbar support curvature adjustment motor -V125-........................................................................................................................................................................................................................................................................................................................................................................................................................................................7185
1.7 Driver seat lumbar support height adjustment motor -V129-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................7186
1.8 Seat forward/back adjustment button -E418-..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7186
1.9 Heated driver seat temperature sensor -G59-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7188
1.10 Driver backrest heating element -Z7-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7188
1.11 Front passenger heated seat temperature sensor -G60-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................7189
1.12 Front passenger backrest heating element -Z9-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................7189
1.13 Front seat heating control module -J774-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7190
1.14 Driver door control module -J386-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7190
1.15 Front passenger door control module -J387-.........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7193
1.16 Driver door contact switch -F2-....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7195
1.17 Front passenger door contact switch -F3-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7196
1.18 Left front window regulator switch -E40-...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................7197
1.19 Front passenger door window regulator switch -E107-................................................................................................................................................................................................................................................................................................................................................................................................................................................................7198
1.20 Mirror adjusting switch -E43-......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7198
1.21 Left rear door control module -J388-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7199
1.22 Right rear door control module -J389-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7200
1.23 Left rear door contact switch -F10-................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7200
1.24 Right rear door contact switch -F11-...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................7201
1.25 Left rear power window switch in left rear door -E52-..............................................................................................................................................................................................................................................................................................................................................................................................................................................................7202
1.26 Right rear window switch in right rear door -E54-..................................................................................................................................................................................................................................................................................................................................................................................................................................................................7203
896 - - Connector Views: Sunroof - 3............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7204
1. Sunroof Connector Views..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7204
1.1 Power sunroof control module -J245-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7204
1.2 Sunroof adjustment regulator -E139-.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7204
897 - - Connector Views: Steering - 3...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7206
1. Steering Connector Views.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7206
1.1 Power steering control module -J500-................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7206
