2012-2020 Volkswagen Golf MK7 Factory Service Manual – PDF DOWNLOAD
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2012-2020 Volkswagen Golf MK7 Factory Service Manual – PDF DOWNLOAD
Language : English
Pages : 7862
Downloadable : Yes
File Type : PDF
Size: 817 MB
TABLE OF CONTENTS:
2012-2020 Volkswagen Golf MK7 Factory Service Manual – PDF DOWNLOAD
Cover.pdf (p.1)...................................................................................................................................................................................................... 1 Contents.pdf (p.2)................................................................................................................................................................................................... 2 00-Maintenance & General Info.pdf (p.3-799).......................................................................................................................................................................... 3 00-01 Fluid Capacity Tables...................................................................................................................................................................................... 3 03 – Maintenance, Diagnosis.................................................................................................................................................................................. 7 1 CC..................................................................................................................................................................................................... 7 2 Tiguan................................................................................................................................................................................................. 9 3 Passat................................................................................................................................................................................................. 10 4 Touareg................................................................................................................................................................................................ 12 5 Eos.................................................................................................................................................................................................... 14 6 Golf/GTI............................................................................................................................................................................................... 15 7 Golf Sportwagen........................................................................................................................................................................................ 17 8 Golf R................................................................................................................................................................................................. 19 9 e-Golf................................................................................................................................................................................................. 20 10 Jetta Hybrid.......................................................................................................................................................................................... 21 11 Jetta/GLI............................................................................................................................................................................................. 22 12 Beetle................................................................................................................................................................................................ 24 13 Beetle Convertible.................................................................................................................................................................................... 26 00-02 Maintenance Intervals...................................................................................................................................................................................... 31 03 – Maintenance, Diagnosis.................................................................................................................................................................................. 35 1 MY 2015 Maintenance Intervals ......................................................................................................................................................................... 35 1.1 MY 2015 Maintenance Intervals - USA.............................................................................................................................................................. 35 1.1.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 35 1.1.2 Service at 20,000€miles.................................................................................................................................................................... 36 1.1.3 Service at 30,000€miles.................................................................................................................................................................... 36 1.1.4 Service at 40,000€miles.................................................................................................................................................................... 37 1.1.5 Service at 50,000€miles.................................................................................................................................................................... 38 1.1.6 Service at 60,000€miles.................................................................................................................................................................... 38 1.1.7 Service at 70,000€miles.................................................................................................................................................................... 39 1.1.8 Service at 80,000€miles.................................................................................................................................................................... 40 1.1.9 Service at 90,000€miles.................................................................................................................................................................... 41 1.1.10 Service at 100,000€miles.................................................................................................................................................................. 41 1.1.11 Service at 110,000€miles.................................................................................................................................................................. 42 1.1.12 Service at 120,000€miles.................................................................................................................................................................. 42 1.1.13 Service at 130,000€miles.................................................................................................................................................................. 44 1.1.14 Service at 140,000€miles.................................................................................................................................................................. 44 1.1.15 Service at 150,000€miles.................................................................................................................................................................. 45 1.1.16 Time-Dependent Maintenance Items.......................................................................................................................................................... 45 1.1.17 Brake Fluid Replacement................................................................................................................................................................... 46 1.2 MY 2015 Maintenance Intervals - Canada........................................................................................................................................................... 46 1.2.1 Service at 15.000€kilometres............................................................................................................................................................... 47 1.2.2 Service at 30.000€kilometres............................................................................................................................................................... 47 1.2.3 Service at 45.000€kilometres............................................................................................................................................................... 48 1.2.4 Service at 60.000€kilometres............................................................................................................................................................... 49 1.2.5 Service at 75.000€kilometres............................................................................................................................................................... 50 1.2.6 Service at 90.000€kilometres............................................................................................................................................................... 51 1.2.7 Service at 105.000€kilometres.............................................................................................................................................................. 51 1.2.8 Service at 120.000€kilometres.............................................................................................................................................................. 52 1.2.9 Service at 135.000€kilometres.............................................................................................................................................................. 53 1.2.10 Service at 150.000€kilometres............................................................................................................................................................. 54 1.2.11 Service at 165.000€kilometres............................................................................................................................................................. 55 1.2.12 Service at 180.000€kilometres............................................................................................................................................................. 56 1.2.13 Service at 195.000€kilometres............................................................................................................................................................. 57 1.2.14 Service at 210.000€kilometres............................................................................................................................................................. 58 1.2.15 Service at 225.000€kilometres............................................................................................................................................................. 58 1.2.16 Time-Dependent Maintenance Items.......................................................................................................................................................... 59 1.2.17 Brake Fluid Replacement................................................................................................................................................................... 60 1.3 MY 2015 Maintenance Intervals - e-Golf........................................................................................................................................................... 60 1.3.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 60 1.3.2 Service at 20,000€miles.................................................................................................................................................................... 61 1.3.3 Service at 30,000€miles.................................................................................................................................................................... 61 1.3.4 Service at 40,000€miles.................................................................................................................................................................... 62 1.3.5 Service at 50,000€miles.................................................................................................................................................................... 63 1.3.6 Service at 60,000€miles.................................................................................................................................................................... 63 1.3.7 Service at 70,000€miles.................................................................................................................................................................... 64 1.3.8 Service at 80,000€miles.................................................................................................................................................................... 65 1.3.9 Service at 90,000€miles.................................................................................................................................................................... 66 1.3.10 Service at 100,000€miles.................................................................................................................................................................. 66 1.3.11 Service at 110,000€miles.................................................................................................................................................................. 67 1.3.12 Service at 120,000€miles.................................................................................................................................................................. 67 1.3.13 Time-Dependent Maintenance Items.......................................................................................................................................................... 68 1.3.14 Brake Fluid Replacement................................................................................................................................................................... 69 2 MY 2014 Maintenance Intervals ......................................................................................................................................................................... 70 2.1 MY 2014 Maintenance Intervals (All Vehicles Except Touareg and Routan) - USA..................................................................................................................... 70 2.1.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 70 2.1.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 71 2.1.3 Service at 30,000€miles.................................................................................................................................................................... 71 2.1.4 Service at 40,000€miles.................................................................................................................................................................... 72 2.1.5 Service at 50,000€miles.................................................................................................................................................................... 73 2.1.6 Service at 60,000€miles.................................................................................................................................................................... 73 2.1.7 Service at 70,000€miles.................................................................................................................................................................... 74 2.1.8 Service at 80,000€miles.................................................................................................................................................................... 75 2.1.9 Service at 90,000€miles.................................................................................................................................................................... 76 2.1.10 Service at 100,000€miles.................................................................................................................................................................. 76 2.1.11 Service at 110,000€miles.................................................................................................................................................................. 77 2.1.12 Service at 120,000€miles.................................................................................................................................................................. 77 2.1.13 Service at 130,000€miles.................................................................................................................................................................. 79 2.1.14 Service at 140,000€miles.................................................................................................................................................................. 79 2.1.15 Service at 150,000€miles.................................................................................................................................................................. 80 2.1.16 Time-Dependent Maintenance Items.......................................................................................................................................................... 80 2.1.17 Brake Fluid Replacement................................................................................................................................................................... 81 2.2 MY 2014 Maintenance Intervals (Touareg Only) - USA............................................................................................................................................... 82 2.2.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 82 2.2.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 82 2.2.3 Service at 30,000€miles.................................................................................................................................................................... 83 2.2.4 Service at 40,000€miles.................................................................................................................................................................... 83 2.2.5 Service at 50,000€miles.................................................................................................................................................................... 85 2.2.6 Service at 60,000€miles.................................................................................................................................................................... 85 2.2.7 Service at 70,000€miles.................................................................................................................................................................... 86 2.2.8 Service at 80,000€miles.................................................................................................................................................................... 86 2.2.9 Service at 90,000€miles.................................................................................................................................................................... 87 2.2.10 Service at 100,000€miles.................................................................................................................................................................. 88 2.2.11 Service at 110,000€miles.................................................................................................................................................................. 88 2.2.12 Service at 120,000€miles.................................................................................................................................................................. 89 2.2.13 Time-Dependent Maintenance Items.......................................................................................................................................................... 90 2.2.14 Brake Fluid Replacement................................................................................................................................................................... 90 2.3 MY 2014 Maintenance Intervals (Only Jetta, Jetta GLI, Jetta Hybrid, The Beetle, The Beetle Convertible, and Golf Wagon) - Canada................................................................. 91 2.3.1 Service at 15.000€kilometres............................................................................................................................................................... 91 2.3.2 Service at 30.000€kilometres............................................................................................................................................................... 92 2.3.3 Service at 45.000€kilometres............................................................................................................................................................... 93 2.3.4 Service at 60.000€kilometres............................................................................................................................................................... 93 2.3.5 Service at 75.000€kilometres............................................................................................................................................................... 95 2.3.6 Service at 90.000€kilometres............................................................................................................................................................... 95 2.3.7 Service at 105.000€kilometres.............................................................................................................................................................. 96 2.3.8 Service at 120.000€kilometres.............................................................................................................................................................. 97 2.3.9 Service at 135.000€kilometres.............................................................................................................................................................. 98 2.3.10 Service at 150.000€kilometres............................................................................................................................................................. 99 2.3.11 Service at 165.000€kilometres............................................................................................................................................................. 100 2.3.12 Service at 180.000€kilometres............................................................................................................................................................. 100 2.3.13 Service at 195.000€kilometres............................................................................................................................................................. 102 2.3.14 Service at 210.000€kilometres............................................................................................................................................................. 103 2.3.15 Service at 225.000€kilometres............................................................................................................................................................. 103 2.3.16 Time-Dependent Maintenance Items.......................................................................................................................................................... 104 2.3.17 Brake Fluid Replacement................................................................................................................................................................... 105 3 MY 2013 Maintenance Intervals ......................................................................................................................................................................... 106 3.1 MY 2013 Maintenance Intervals (All Vehicles Except Touareg and Routan) - USA..................................................................................................................... 106 3.1.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 106 3.1.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 107 3.1.3 Service at 30,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 107 3.1.4 Service at 40,000€miles.................................................................................................................................................................... 108 3.1.5 Service at 50,000€miles.................................................................................................................................................................... 109 3.1.6 Service at 60,000€miles.................................................................................................................................................................... 109 3.1.7 Service at 70,000€miles.................................................................................................................................................................... 110 3.1.8 Service at 80,000€miles.................................................................................................................................................................... 110 3.1.9 Service at 90,000€miles.................................................................................................................................................................... 111 3.1.10 Service at 100,000€miles.................................................................................................................................................................. 112 3.1.11 Service at 110,000€miles.................................................................................................................................................................. 112 3.1.12 Service at 120,000€miles.................................................................................................................................................................. 113 3.1.13 Service at 130,000€miles.................................................................................................................................................................. 114 3.1.14 Time-Dependent Maintenance Items.......................................................................................................................................................... 114 3.1.15 Brake Fluid Replacement................................................................................................................................................................... 115 3.2 MY 2013 Maintenance Intervals (Touareg Only) - USA............................................................................................................................................... 116 3.2.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 116 3.2.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 116 3.2.3 Service at 30,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 117 3.2.4 Service at 40,000€miles.................................................................................................................................................................... 118 3.2.5 Service at 50,000€miles.................................................................................................................................................................... 119 3.2.6 Service at 60,000€miles.................................................................................................................................................................... 119 3.2.7 Service at 70,000€miles.................................................................................................................................................................... 120 3.2.8 Service at 80,000€miles.................................................................................................................................................................... 120 3.2.9 Service at 90,000€miles.................................................................................................................................................................... 121 3.2.10 Service at 100,000€miles.................................................................................................................................................................. 122 3.2.11 Service at 110,000€miles.................................................................................................................................................................. 122 3.2.12 Service at 120,000€miles.................................................................................................................................................................. 123 3.2.13 Time-Dependent Maintenance Items.......................................................................................................................................................... 124 3.2.14 Brake Fluid Replacement................................................................................................................................................................... 124 3.3 MY 2013 Maintenance Intervals (All Vehicles) - Canada............................................................................................................................................ 125 3.3.1 Service at 15.000€km....................................................................................................................................................................... 125 3.3.2 Service at 30.000€km....................................................................................................................................................................... 126 3.3.3 Service at 60.000€km....................................................................................................................................................................... 127 3.3.4 Service at 75.000€km....................................................................................................................................................................... 128 3.3.5 Service at 90.000€km....................................................................................................................................................................... 128 3.3.6 Service at 105.000€km...................................................................................................................................................................... 129 3.3.7 Service at 120.000€km...................................................................................................................................................................... 130 3.3.8 Service at 135.000€km...................................................................................................................................................................... 131 3.3.9 Service at 150.000€km...................................................................................................................................................................... 132 3.3.10 Service at 165.000€km..................................................................................................................................................................... 133 3.3.11 Service at 180.000€km..................................................................................................................................................................... 133 3.3.12 Service at 195.000€km..................................................................................................................................................................... 135 3.3.13 Time-Dependent Maintenance Items.......................................................................................................................................................... 135 3.3.14 Brake Fluid Replacement................................................................................................................................................................... 136 4 MY 2012 Maintenance Intervals ......................................................................................................................................................................... 137 4.1 MY 2012 Maintenance Intervals (All Vehicles Except Touareg and Routan) - USA..................................................................................................................... 137 4.1.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 137 4.1.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 138 4.1.3 Service at 30,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 138 4.1.4 Service at 40,000€miles.................................................................................................................................................................... 139 4.1.5 Service at 50,000€miles.................................................................................................................................................................... 140 4.1.6 Service at 60,000€miles.................................................................................................................................................................... 140 4.1.7 Service at 70,000€miles.................................................................................................................................................................... 141 4.1.8 Service at 80,000€miles.................................................................................................................................................................... 141 4.1.9 Service at 90,000€miles.................................................................................................................................................................... 142 4.1.10 Service at 100,000€miles.................................................................................................................................................................. 143 4.1.11 Service at 110,000€miles.................................................................................................................................................................. 143 4.1.12 Service at 120,000€miles.................................................................................................................................................................. 144 4.1.13 Service at 130,000€miles.................................................................................................................................................................. 145 4.1.14 Time-Dependent Maintenance Items.......................................................................................................................................................... 145 4.1.15 Brake Fluid Replacement................................................................................................................................................................... 146 4.2 MY 2012 Maintenance Intervals (Touareg Only) - USA............................................................................................................................................... 147 4.2.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 147 4.2.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 147 4.2.3 Service at 30,000€miles (Included in the Volkswagen Carefree Maintenance Program).......................................................................................................... 148 4.2.4 Service at 40,000€miles.................................................................................................................................................................... 149 4.2.5 Service at 50,000€miles.................................................................................................................................................................... 150 4.2.6 Service at 60,000€miles.................................................................................................................................................................... 150 4.2.7 Service at 70,000€miles.................................................................................................................................................................... 151 4.2.8 Service at 80,000€miles.................................................................................................................................................................... 151 4.2.9 Service at 90,000€miles.................................................................................................................................................................... 152 4.2.10 Service at 100,000€miles.................................................................................................................................................................. 153 4.2.11 Service at 110,000€miles.................................................................................................................................................................. 153 4.2.12 Service at 120,000€miles.................................................................................................................................................................. 154 4.2.13 Time-Dependent Maintenance Items.......................................................................................................................................................... 155 4.2.14 Brake Fluid Replacement................................................................................................................................................................... 155 4.3 MY 2012 Maintenance Intervals - Canada........................................................................................................................................................... 156 4.3.1 Service at 15.000€km....................................................................................................................................................................... 156 4.3.2 Service at 30.000€km....................................................................................................................................................................... 157 4.3.3 Service at 45.000€km....................................................................................................................................................................... 158 4.3.4 Service at 60.000€km....................................................................................................................................................................... 158 4.3.5 Service at 75.000€km....................................................................................................................................................................... 159 4.3.6 Service at 90.000€km....................................................................................................................................................................... 160 4.3.7 Service at 105.000€km...................................................................................................................................................................... 161 4.3.8 Service at 120.000€km...................................................................................................................................................................... 161 4.3.9 Service at 135.000€km...................................................................................................................................................................... 163 4.3.10 Service at 150.000€km..................................................................................................................................................................... 163 4.3.11 Service at 165.000€km..................................................................................................................................................................... 164 4.3.12 Service at 180.000€km..................................................................................................................................................................... 165 4.3.13 Service at 195.000€km..................................................................................................................................................................... 166 4.3.14 Time-Dependent Maintenance Items.......................................................................................................................................................... 167 4.3.15 Brake Fluid Replacement................................................................................................................................................................... 167 4.4 MY 2012 Maintenance Intervals - Routan - USA..................................................................................................................................................... 168 4.4.1 Service at 8,000 Miles..................................................................................................................................................................... 168 4.4.2 Service at 16,000 Miles.................................................................................................................................................................... 168 4.4.3 Service at 24,000 Miles.................................................................................................................................................................... 169 4.4.4 Service at 32,000 Miles.................................................................................................................................................................... 169 4.4.5 Service at 40,000 Miles.................................................................................................................................................................... 169 4.4.6 Service at 48,000 Miles.................................................................................................................................................................... 169 4.4.7 Service at 56,000 Miles.................................................................................................................................................................... 169 4.4.8 Service at 64,000 Miles.................................................................................................................................................................... 170 4.4.9 Service at 72,000 Miles.................................................................................................................................................................... 170 4.4.10 Service at 80,000 Miles................................................................................................................................................................... 170 4.4.11 Service at 88,000 Miles................................................................................................................................................................... 170 4.4.12 Service at 96,000 Miles................................................................................................................................................................... 171 4.4.13 Service at 104,000 Miles.................................................................................................................................................................. 171 4.4.14 Service at 112,000 Miles.................................................................................................................................................................. 171 4.4.15 Service at 120,000 Miles.................................................................................................................................................................. 171 4.4.16 Service at 128,000 miles.................................................................................................................................................................. 172 4.4.17 Service at 136,000 Miles.................................................................................................................................................................. 172 4.4.18 Service at 144,000 Miles.................................................................................................................................................................. 172 4.4.19 Service at 152,000 Miles.................................................................................................................................................................. 172 4.5 MY 2012 Maintenance Intervals - Routan - Canada.................................................................................................................................................. 173 4.5.1 Service at 13,000 Kilometers............................................................................................................................................................... 173 4.5.2 Service at 26,000 Kilometers............................................................................................................................................................... 173 4.5.3 Service at 39,000 Kilometers............................................................................................................................................................... 173 4.5.4 Service at 52,000 Kilometers............................................................................................................................................................... 174 4.5.5 Service at 65,000Kilometers................................................................................................................................................................ 174 4.5.6 Service at 78,000 Kilometers............................................................................................................................................................... 174 4.5.7 Service at 91,000 Kilometers............................................................................................................................................................... 174 4.5.8 Service at 104,000 Kilometers.............................................................................................................................................................. 174 4.5.9 Service at 117,000 Kilometers.............................................................................................................................................................. 175 4.5.10 Service at 130,000 Kilometers............................................................................................................................................................. 175 4.5.11 Service at 143,000 Kilometers............................................................................................................................................................. 175 4.5.12 Service at 156,000 Kilometers............................................................................................................................................................. 175 4.5.13 Service at 169,000 Kilometers............................................................................................................................................................. 176 4.5.14 Service at 182,000 Kilometers............................................................................................................................................................. 176 4.5.15 Service at 195,000 Kilometers............................................................................................................................................................. 176 4.5.16 Service at 208,000 Kilometers............................................................................................................................................................. 176 4.5.17 Service at 221,000 Kilometers............................................................................................................................................................. 176 4.5.18 Service at 234,000 Kilometers............................................................................................................................................................. 176 4.5.19 Service at 247,000 Kilometers............................................................................................................................................................. 177 5 MY 2011 Maintenance Intervals.......................................................................................................................................................................... 178 5.1 MY 2011 Maintenance Intervals (Except Routan) - USA.............................................................................................................................................. 178 5.1.1 Time Dependent Service..................................................................................................................................................................... 178 5.1.2 Service at 10,000€miles.................................................................................................................................................................... 179 5.1.3 Service at 20,000€miles.................................................................................................................................................................... 179 5.1.4 Service at 30,000€miles.................................................................................................................................................................... 180 5.1.5 Service at 40,000 miles.................................................................................................................................................................... 181 5.1.6 Service at 50,000 miles.................................................................................................................................................................... 182 5.1.7 Service at 60,000 miles.................................................................................................................................................................... 182 5.1.8 Service at 70,000 miles.................................................................................................................................................................... 183 5.1.9 Service at 80,000 miles.................................................................................................................................................................... 184 5.1.10 Service at 90,000 miles................................................................................................................................................................... 185 5.1.11 Service at 100,000 miles.................................................................................................................................................................. 186 5.1.12 Service at 110,000 miles.................................................................................................................................................................. 186 5.1.13 Service at 120,000 miles.................................................................................................................................................................. 187 5.1.14 Service at 130,000 miles.................................................................................................................................................................. 188 5.2 MY 2011 Maintenance Intervals (Except Routan) - Canada........................................................................................................................................... 189 5.2.1 Time Dependent Service..................................................................................................................................................................... 189 5.2.2 Service at 15,000€kilometers............................................................................................................................................................... 190 5.2.3 Service at 30,000€kilometers............................................................................................................................................................... 191 5.2.4 Service at 45,000€kilometers............................................................................................................................................................... 191 5.2.5 Service at 60,000€kilometers............................................................................................................................................................... 192 5.2.6 Service at 75,000€kilometers............................................................................................................................................................... 193 5.2.7 Service at 90,000€kilometers............................................................................................................................................................... 194 5.2.8 Service at 105,000€kilometers.............................................................................................................................................................. 195 5.2.9 Service at 120,000€kilometers.............................................................................................................................................................. 195 5.2.10 Service at 135,000€kilometers............................................................................................................................................................. 197 5.2.11 Service at 150,000€kilometers............................................................................................................................................................. 197 5.2.12 Service at 165,000€kilometers............................................................................................................................................................. 198 5.2.13 Service at 180,000€kilometers............................................................................................................................................................. 199 5.2.14 Service at 195,000€kilometers............................................................................................................................................................. 200 5.3 MY 2011 Maintenance Intervals - Routan - USA..................................................................................................................................................... 202 5.3.1 Service at 8,000 miles..................................................................................................................................................................... 202 5.3.2 Service at 16,000 miles.................................................................................................................................................................... 202 5.3.3 Service at 24,000 miles.................................................................................................................................................................... 202 5.3.4 Service at 32,000 miles.................................................................................................................................................................... 203 5.3.5 Service at 40,000 miles.................................................................................................................................................................... 203 5.3.6 Service at 48,000 miles.................................................................................................................................................................... 203 5.3.7 Service at 56,000 miles.................................................................................................................................................................... 203 5.3.8 Service at 64,000 miles.................................................................................................................................................................... 203 5.3.9 Service at 72,000 miles.................................................................................................................................................................... 204 5.3.10 Service at 80,000 miles................................................................................................................................................................... 204 5.3.11 Service at 88,000 miles................................................................................................................................................................... 204 5.3.12 Service at 96,000 miles................................................................................................................................................................... 204 5.3.13 Service at 104,000 miles.................................................................................................................................................................. 205 5.3.14 Service at 112,000 miles.................................................................................................................................................................. 205 5.3.15 Service at 120,000 miles.................................................................................................................................................................. 205 5.3.16 Service at 128,000 miles.................................................................................................................................................................. 205 5.3.17 Service at 136,000 miles.................................................................................................................................................................. 205 5.3.18 Service at 144,000 miles.................................................................................................................................................................. 205 5.3.19 Service at 152,000 miles.................................................................................................................................................................. 206 5.4 MY 2011 Maintenance Intervals - Routan - Canada.................................................................................................................................................. 206 5.4.1 Service at 13,000 kilometers............................................................................................................................................................... 206 5.4.2 Service at 26,000 kilometers............................................................................................................................................................... 207 5.4.3 Service at 39,000 kilometers............................................................................................................................................................... 207 5.4.4 Service at 52,000 kilometers............................................................................................................................................................... 207 5.4.5 Service at 65,000 kilometers............................................................................................................................................................... 207 5.4.6 Service at 78,000 kilometers............................................................................................................................................................... 207 5.4.7 Service at 91,000 kilometers............................................................................................................................................................... 208 5.4.8 Service at 104,000 kilometers.............................................................................................................................................................. 208 5.4.9 Service at 117,000 kilometers.............................................................................................................................................................. 208 5.4.10 Service at 130,000 kilometers............................................................................................................................................................. 208 5.4.11 Service at 143,000 kilometers............................................................................................................................................................. 209 5.4.12 Service at 156,000 kilometers............................................................................................................................................................. 209 5.4.13 Service at 169,000 kilometers............................................................................................................................................................. 209 5.4.14 Service at 182,000 kilometers............................................................................................................................................................. 209 5.4.15 Service at 195,000 kilometers............................................................................................................................................................. 209 5.4.16 Service at 208,000 kilometers............................................................................................................................................................. 210 5.4.17 Service at 221,000 kilometers............................................................................................................................................................. 210 5.4.18 Service at 234,000 kilometers............................................................................................................................................................. 210 5.4.19 Service at 247,000 kilometers............................................................................................................................................................. 210 6 MY 2010 Maintenance Intervals.......................................................................................................................................................................... 211 6.1 MY 2010 Maintenance Intervals - USA.............................................................................................................................................................. 211 6.1.1 Time Dependent Service..................................................................................................................................................................... 211 6.1.2 Service at Each 5,000 miles through 35,000 miles........................................................................................................................................... 212 6.1.3 Service at 10,000€miles.................................................................................................................................................................... 212 6.1.4 Service at 20,000€miles.................................................................................................................................................................... 212 6.1.5 Service at 30,000€miles.................................................................................................................................................................... 213 6.1.6 Service at 40,000€miles and each 5,000 miles After......................................................................................................................................... 213 6.1.7 Service at 40,000 miles.................................................................................................................................................................... 213 6.1.8 Service at 50,000 miles.................................................................................................................................................................... 215 6.1.9 Service at 60,000 miles.................................................................................................................................................................... 215 6.1.10 Service at 70,000 miles................................................................................................................................................................... 216 6.1.11 Service at 80,000 miles................................................................................................................................................................... 216 6.1.12 Service at 90,000 miles................................................................................................................................................................... 217 6.1.13 Service at 100,000 miles.................................................................................................................................................................. 218 6.1.14 Service at 110,000 miles.................................................................................................................................................................. 218 6.1.15 Service at 120,000 miles.................................................................................................................................................................. 219 6.2 MY 2010 Maintenance Intervals - Canada........................................................................................................................................................... 220 6.2.1 Time Dependent Service..................................................................................................................................................................... 220 6.2.2 Service at 15,000€kilometers or one year from vehicle in-service date...................................................................................................................... 221 6.2.3 Service at 30,000€kilometers............................................................................................................................................................... 221 6.2.4 Service at 45,000€kilometers............................................................................................................................................................... 222 6.2.5 Service at 60,000€kilometers............................................................................................................................................................... 222 6.2.6 Service at 75,000€kilometers............................................................................................................................................................... 224 6.2.7 Service at 90.000€kilometers............................................................................................................................................................... 224 6.2.8 Service at 105,000€kilometers.............................................................................................................................................................. 225 6.2.9 Service at 120,000€kilometers.............................................................................................................................................................. 225 6.2.10 Service at 135,000€kilometers............................................................................................................................................................. 226 6.2.11 Service at 150,000€kilometers............................................................................................................................................................. 227 6.2.12 Service at 165,000€kilometers............................................................................................................................................................. 227 6.2.13 Service at 180,000€kilometers............................................................................................................................................................. 228 6.3 MY 2010 Maintenance Intervals - Routan - USA..................................................................................................................................................... 229 6.3.1 Service at 6,000 miles..................................................................................................................................................................... 230 6.3.2 Service at 12,000 miles.................................................................................................................................................................... 230 6.3.3 Service at 18,000 miles.................................................................................................................................................................... 230 6.3.4 Service at 24,000 miles.................................................................................................................................................................... 231 6.3.5 Service at 30,000 miles.................................................................................................................................................................... 231 6.3.6 Service at 36,000 miles.................................................................................................................................................................... 231 6.3.7 Service at 42,000 miles.................................................................................................................................................................... 231 6.3.8 Service at 48,000 miles.................................................................................................................................................................... 231 6.3.9 Service at 54,000 miles.................................................................................................................................................................... 231 6.3.10 Service at 60,000 miles................................................................................................................................................................... 232 6.3.11 Service at 66,000 miles................................................................................................................................................................... 232 6.3.12 Service at 72,000 miles................................................................................................................................................................... 232 6.3.13 Service at 78,000 miles................................................................................................................................................................... 232 6.3.14 Service at 84,000 miles................................................................................................................................................................... 232 6.3.15 Service at 90,000 miles................................................................................................................................................................... 232 6.3.16 Service at 96,000 miles................................................................................................................................................................... 233 6.3.17 Service at 102,000 miles.................................................................................................................................................................. 233 6.3.18 Service at 108,000 miles.................................................................................................................................................................. 233 6.3.19 Service at 114,000 miles.................................................................................................................................................................. 233 6.3.20 Service at 120,000 miles.................................................................................................................................................................. 233 6.3.21 Service at 126,000 miles.................................................................................................................................................................. 234 6.3.22 Service at 132,000 miles.................................................................................................................................................................. 234 6.3.23 Service at 138,000 miles.................................................................................................................................................................. 234 6.3.24 Service at 144,000 miles.................................................................................................................................................................. 234 6.3.25 Service at 150,000 miles.................................................................................................................................................................. 234 6.4 MY 2010 Maintenance Intervals - Routan - Canada.................................................................................................................................................. 235 6.4.1 Service at 10,000 kilometers............................................................................................................................................................... 235 6.4.2 Service at 20,000 kilometers............................................................................................................................................................... 235 6.4.3 Service at 30,000 kilometers............................................................................................................................................................... 236 6.4.4 Service at 40,000 kilometers............................................................................................................................................................... 236 6.4.5 Service at 50,000 kilometers............................................................................................................................................................... 236 6.4.6 Service at 60,000 kilometers............................................................................................................................................................... 236 6.4.7 Service at 70,000 kilometers............................................................................................................................................................... 236 6.4.8 Service at 80,000 kilometers............................................................................................................................................................... 236 6.4.9 Service at 90,000 kilometers............................................................................................................................................................... 236 6.4.10 Service at 100,000 kilometers............................................................................................................................................................. 237 6.4.11 Service at 110,000 kilometers............................................................................................................................................................. 237 6.4.12 Service at 120,000 kilometers............................................................................................................................................................. 237 6.4.13 Service at 130,000 kilometers............................................................................................................................................................. 237 6.4.14 Service at 140,000 kilometers............................................................................................................................................................. 237 6.4.15 Service at 150,000 kilometers............................................................................................................................................................. 237 6.4.16 Service at 160,000 kilometers............................................................................................................................................................. 238 6.4.17 Service at 170,000 kilometers............................................................................................................................................................. 238 6.4.18 Service at 180,000 kilometers............................................................................................................................................................. 238 6.4.19 Service at 190,000 kilometers............................................................................................................................................................. 238 6.4.20 Service at 200,000 kilometers............................................................................................................................................................. 238 6.4.21 Service at 210,000 kilometers............................................................................................................................................................. 239 6.4.22 Service at 220,000 kilometers............................................................................................................................................................. 239 6.4.23 Service at 230,000 kilometers............................................................................................................................................................. 239 6.4.24 Service at 240,000 kilometers............................................................................................................................................................. 239 6.4.25 Service at 250,000 kilometers............................................................................................................................................................. 239 7 MY 2009 Maintenance Intervals.......................................................................................................................................................................... 240 7.1 MY 2009 Maintenance Intervals - USA.............................................................................................................................................................. 240 7.1.1 Time-Dependent Maintenance Items........................................................................................................................................................... 240 7.1.2 Service every 5,000 miles.................................................................................................................................................................. 241 7.1.3 Service at 10,000 miles.................................................................................................................................................................... 241 7.1.4 Service at 20,000 miles.................................................................................................................................................................... 241 7.1.5 Service at 30,000 miles.................................................................................................................................................................... 242 7.1.6 Service at 40,000 miles.................................................................................................................................................................... 242 7.1.7 Service at 50,000 miles.................................................................................................................................................................... 243 7.1.8 Service at 60,000 miles.................................................................................................................................................................... 244 7.1.9 Service at 70,000 miles.................................................................................................................................................................... 244 7.1.10 Service at 80,000 miles................................................................................................................................................................... 245 7.1.11 Service at 90,000 miles................................................................................................................................................................... 246 7.1.12 Service at 100,000 miles.................................................................................................................................................................. 246 7.1.13 Service at 110,000 miles.................................................................................................................................................................. 247 7.1.14 Service at 120,000 miles.................................................................................................................................................................. 247 7.1.15 Service at 130,000 miles.................................................................................................................................................................. 248 7.2 MY 2009 Maintenance Intervals - Canada........................................................................................................................................................... 249 7.2.1 Time Dependent Service..................................................................................................................................................................... 249 7.2.2 Service at 15,000€kilometers or one year from vehicle in-service date...................................................................................................................... 250 7.2.3 Service at 30,000€kilometers............................................................................................................................................................... 250 7.2.4 Service at 45,000€kilometers............................................................................................................................................................... 251 7.2.5 Service at 60,000€kilometers............................................................................................................................................................... 251 7.2.6 Service at 75,000€kilometers............................................................................................................................................................... 252 7.2.7 Service at 90.000€kilometers............................................................................................................................................................... 253 7.2.8 Service at 105,000€kilometers.............................................................................................................................................................. 253 7.2.9 Service at 120,000€kilometers.............................................................................................................................................................. 254 7.2.10 Service at 135,000€kilometers............................................................................................................................................................. 255 7.2.11 Service at 150,000€kilometers............................................................................................................................................................. 256 7.2.12 Service at 165,000€kilometers............................................................................................................................................................. 256 7.2.13 Service at 180,000€kilometers............................................................................................................................................................. 257 7.3 MY 2009 Maintenance Intervals - Routan - USA..................................................................................................................................................... 258 7.3.1 Service at 6,000 miles..................................................................................................................................................................... 259 7.3.2 Service at 12,000 miles.................................................................................................................................................................... 259 7.3.3 Service at 18,000 miles.................................................................................................................................................................... 259 7.3.4 Service at 24,000 miles.................................................................................................................................................................... 260 7.3.5 Service at 30,000 miles.................................................................................................................................................................... 260 7.3.6 Service at 36,000 miles.................................................................................................................................................................... 260 7.3.7 Service at 42,000 miles.................................................................................................................................................................... 260 7.3.8 Service at 48,000 miles.................................................................................................................................................................... 260 7.3.9 Service at 54,000 miles.................................................................................................................................................................... 260 7.3.10 Service at 60,000 miles................................................................................................................................................................... 260 7.3.11 Service at 66,000 miles................................................................................................................................................................... 261 7.3.12 Service at 72,000 miles................................................................................................................................................................... 261 7.3.13 Service at 78,000 miles................................................................................................................................................................... 261 7.3.14 Service at 84,000 miles................................................................................................................................................................... 261 7.3.15 Service at 90,000 miles................................................................................................................................................................... 261 7.3.16 Service at 96,000 miles................................................................................................................................................................... 261 7.3.17 Service at 102,000 miles.................................................................................................................................................................. 262 7.3.18 Service at 108,000 miles.................................................................................................................................................................. 262 7.3.19 Service at 114,000 miles.................................................................................................................................................................. 262 7.3.20 Service at 120,000 miles.................................................................................................................................................................. 262 7.3.21 Service at 126,000 miles.................................................................................................................................................................. 262 7.3.22 Service at 132,000 miles.................................................................................................................................................................. 262 7.3.23 Service at 138,000 miles.................................................................................................................................................................. 262 7.3.24 Service at 144,000 miles.................................................................................................................................................................. 263 7.3.25 Service at 150,000 miles.................................................................................................................................................................. 263 7.4 MY 2009 Maintenance Intervals - Routan - Canada.................................................................................................................................................. 263 7.4.1 Service at 10,000 kilometers............................................................................................................................................................... 263 7.4.2 Service at 20,000 kilometers............................................................................................................................................................... 264 7.4.3 Service at 30,000 kilometers............................................................................................................................................................... 264 7.4.4 Service at 40,000 kilometers............................................................................................................................................................... 264 7.4.5 Service at 50,000 kilometers............................................................................................................................................................... 264 7.4.6 Service at 60,000 kilometers............................................................................................................................................................... 264 7.4.7 Service at 70,000 kilometers............................................................................................................................................................... 264 7.4.8 Service at 80,000 kilometers............................................................................................................................................................... 264 7.4.9 Service at 90,000 kilometers............................................................................................................................................................... 265 7.4.10 Service at 100,000 kilometers............................................................................................................................................................. 265 7.4.11 Service at 110,000 kilometers............................................................................................................................................................. 265 7.4.12 Service at 120,000 kilometers............................................................................................................................................................. 265 7.4.13 Service at 130,000 kilometers............................................................................................................................................................. 265 7.4.14 Service at 140,000 kilometers............................................................................................................................................................. 265 7.4.15 Service at 150,000 kilometers............................................................................................................................................................. 265 7.4.16 Service at 160,000 kilometers............................................................................................................................................................. 266 7.4.17 Service at 170,000 kilometers............................................................................................................................................................. 266 7.4.18 Service at 180,000 kilometers............................................................................................................................................................. 266 7.4.19 Service at 190,000 kilometers............................................................................................................................................................. 266 7.4.20 Service at 200,000 kilometers............................................................................................................................................................. 266 7.4.21 Service at 210,000 kilometers............................................................................................................................................................. 267 7.4.22 Service at 220,000 kilometers............................................................................................................................................................. 267 7.4.23 Service at 230,000 kilometers............................................................................................................................................................. 267 7.4.24 Service at 240,000 kilometers............................................................................................................................................................. 267 7.4.25 Service at 250,000 kilometers............................................................................................................................................................. 267 8 MY 2008 Maintenance Intervals.......................................................................................................................................................................... 268 8.1 MY 2008 Maintenance Intervals - USA.............................................................................................................................................................. 268 8.1.1 Time-Dependent Maintenance Items........................................................................................................................................................... 268 8.1.2 Service at 5,000 miles..................................................................................................................................................................... 268 8.1.3 Service at 10,000 miles.................................................................................................................................................................... 269 8.1.4 Service at 20,000 miles.................................................................................................................................................................... 269 8.1.5 Service at 30,000 miles.................................................................................................................................................................... 270 8.1.6 Service at 40,000 miles.................................................................................................................................................................... 270 8.1.7 Service at 50,000 miles.................................................................................................................................................................... 272 8.1.8 Service at 60,000 miles.................................................................................................................................................................... 272 8.1.9 Service at 70,000 miles.................................................................................................................................................................... 273 8.1.10 Service at 80,000 miles................................................................................................................................................................... 274 8.1.11 Service at 90,000 miles................................................................................................................................................................... 275 8.1.12 Service at 100,000 miles.................................................................................................................................................................. 276 8.1.13 Service at 110,000 miles.................................................................................................................................................................. 277 8.1.14 Service at 120,000 miles.................................................................................................................................................................. 277 8.2 MY 2008 Maintenance Intervals - Canada........................................................................................................................................................... 279 8.2.1 Time-Dependent Maintenance Items........................................................................................................................................................... 279 8.2.2 Service at 8,000 kilometers................................................................................................................................................................ 279 8.2.3 Service at 16,000 kilometers............................................................................................................................................................... 279 8.2.4 Service at 32,000 kilometers............................................................................................................................................................... 280 8.2.5 Service at 48,000 kilometers............................................................................................................................................................... 281 8.2.6 Service at 64,000 kilometers............................................................................................................................................................... 281 8.2.7 Service at 80,000 kilometers............................................................................................................................................................... 283 8.2.8 Service at 96,000 kilometers............................................................................................................................................................... 283 8.2.9 Service at 112,000 kilometers.............................................................................................................................................................. 284 8.2.10 Service at 128,000 kilometers............................................................................................................................................................. 285 8.2.11 Service at 144,000 kilometers............................................................................................................................................................. 286 8.2.12 Service at 160,000 kilometers............................................................................................................................................................. 286 8.2.13 Service at 176,000 kilometers............................................................................................................................................................. 287 8.2.14 Service at 180,000 kilometers............................................................................................................................................................. 288 9 MY 2007 Maintenance Intervals.......................................................................................................................................................................... 290 9.1 MY 2007 Maintenance Intervals - USA.............................................................................................................................................................. 290 9.1.1 Time-Dependent Maintenance Items........................................................................................................................................................... 290 9.1.2 Service at 5,000 miles..................................................................................................................................................................... 291 9.1.3 Service at 10,000 miles.................................................................................................................................................................... 291 9.1.4 Service at 20,000 miles.................................................................................................................................................................... 291 9.1.5 Service at 30,000 miles.................................................................................................................................................................... 292 9.1.6 Service at 40,000 miles.................................................................................................................................................................... 292 9.1.7 Service at 50,000 miles.................................................................................................................................................................... 293 9.1.8 Service at 60,000 miles.................................................................................................................................................................... 294 9.1.9 Service at 70,000 miles.................................................................................................................................................................... 295 9.1.10 Service at 80,000 miles................................................................................................................................................................... 295 9.1.11 Service at 90,000 miles................................................................................................................................................................... 296 9.1.12 Service at 100,000 miles.................................................................................................................................................................. 297 9.1.13 Service at 110,000 miles.................................................................................................................................................................. 298 9.1.14 Service at 120,000 miles.................................................................................................................................................................. 298 9.2 MY 2007 Maintenance Intervals - Canada........................................................................................................................................................... 300 9.2.1 Time-Dependent Maintenance Items........................................................................................................................................................... 300 9.2.2 Service at 8,000 kilometers................................................................................................................................................................ 300 9.2.3 Service at 16,000 kilometers............................................................................................................................................................... 301 9.2.4 Service at 32,000 kilometers............................................................................................................................................................... 301 9.2.5 Service at 48,000 kilometers............................................................................................................................................................... 302 9.2.6 Service at 64,000 kilometers............................................................................................................................................................... 302 9.2.7 Service at 80,000 kilometers............................................................................................................................................................... 303 9.2.8 Service at 96,000 kilometers............................................................................................................................................................... 304 9.2.9 Service at 112,000 kilometers.............................................................................................................................................................. 305 9.2.10 Service at 128,000 kilometers............................................................................................................................................................. 305 9.2.11 Service at 144,000 kilometers............................................................................................................................................................. 306 9.2.12 Service at 160,000 kilometers............................................................................................................................................................. 306 9.2.13 Service at 176,000 kilometers............................................................................................................................................................. 307 9.2.14 Service at 180,000 kilometers............................................................................................................................................................. 308 10 MY 2006 Maintenance Intervals......................................................................................................................................................................... 310 10.1 MY 2006 Maintenance Intervals - USA............................................................................................................................................................. 310 10.1.1 Time-Dependent Maintenance Items.......................................................................................................................................................... 310 10.1.2 Service at 5,000 miles.................................................................................................................................................................... 311 10.1.3 Service at 10,000 miles................................................................................................................................................................... 311 10.1.4 Service at 15,000 miles................................................................................................................................................................... 311 10.1.5 Service at 20,000 miles................................................................................................................................................................... 311 10.1.6 Service at 25,000 miles................................................................................................................................................................... 312 10.1.7 Service at 30,000 miles................................................................................................................................................................... 312 10.1.8 Service at 35,000 miles................................................................................................................................................................... 313 10.1.9 Service at 40,000 miles................................................................................................................................................................... 313 10.1.10 Service at 45,000 miles.................................................................................................................................................................. 314 10.1.11 Service at 50,000 miles.................................................................................................................................................................. 314 10.1.12 Service at 55,000 miles.................................................................................................................................................................. 315 10.1.13 Service at 60,000 miles.................................................................................................................................................................. 315 10.1.14 Service at 65,000 miles.................................................................................................................................................................. 316 10.1.15 Service at 70,000 miles.................................................................................................................................................................. 316 10.1.16 Service at 75,000 miles.................................................................................................................................................................. 316 10.1.17 Service at 80,000 miles.................................................................................................................................................................. 316 10.1.18 Service at 85,000 miles.................................................................................................................................................................. 318 10.1.19 Service at 90,000 miles.................................................................................................................................................................. 318 10.1.20 Service at 95,000 miles.................................................................................................................................................................. 318 10.1.21 Service at 100,000 miles................................................................................................................................................................. 318 10.1.22 Service at 105,000 miles................................................................................................................................................................. 319 10.2 MY 2006 Maintenance Intervals - Canada.......................................................................................................................................................... 320 10.2.1 Time-Dependent Maintenance Items.......................................................................................................................................................... 320 10.2.2 Service at 8,000 kilometers............................................................................................................................................................... 321 10.2.3 Service at 16,000 kilometers.............................................................................................................................................................. 321 10.2.4 Service at 24,000 kilometers.............................................................................................................................................................. 321 10.2.5 Service at 32,000 kilometers.............................................................................................................................................................. 321 10.2.6 Service at 40,000 kilometers.............................................................................................................................................................. 322 10.2.7 Service at 48,000 kilometers.............................................................................................................................................................. 322 10.2.8 Service at 56,000 kilometers.............................................................................................................................................................. 323 10.2.9 Service at 64,000 kilometers.............................................................................................................................................................. 323 10.2.10 Service at 72,000 kilometers............................................................................................................................................................. 324 10.2.11 Service at 80,000 kilometers............................................................................................................................................................. 324 10.2.12 Service at 88,000 kilometers............................................................................................................................................................. 325 10.2.13 Service at 96,000 kilometers............................................................................................................................................................. 325 10.2.14 Service at 104,000 kilometers............................................................................................................................................................ 326 10.2.15 Service at 112,000 kilometers............................................................................................................................................................ 326 10.2.16 Service at 120,000 kilometers............................................................................................................................................................ 326 10.2.17 Service at 128,000 kilometers............................................................................................................................................................ 326 10.2.18 Service at 136,000 kilometers............................................................................................................................................................ 328 10.2.19 Service at 144,000 kilometers............................................................................................................................................................ 328 10.2.20 Service at 152,000 kilometers............................................................................................................................................................ 328 10.2.21 Service at 160,000 kilometers............................................................................................................................................................ 328 10.2.22 Service at 168,000 kilometers............................................................................................................................................................ 329 11 MY 2005 Maintenance Intervals......................................................................................................................................................................... 330 11.1 MY 2005 Maintenance Intervals - USA............................................................................................................................................................. 330 11.1.1 Time-Dependent Maintenance Items.......................................................................................................................................................... 330 11.1.2 Service at 5,000 miles.................................................................................................................................................................... 331 11.1.3 Service at 10,000 miles................................................................................................................................................................... 331 11.1.4 Service at 15,000 miles................................................................................................................................................................... 331 11.1.5 Service at 20,000 miles................................................................................................................................................................... 331 11.1.6 Service at 25,000 miles................................................................................................................................................................... 332 11.1.7 Service at 30,000 miles................................................................................................................................................................... 332 11.1.8 Service at 35,000 miles................................................................................................................................................................... 333 11.1.9 Service at 40,000 miles................................................................................................................................................................... 333 11.1.10 Service at 45,000 miles.................................................................................................................................................................. 334 11.1.11 Service at 50,000 miles.................................................................................................................................................................. 334 11.1.12 Service at 55,000 miles.................................................................................................................................................................. 334 11.1.13 Service at 60,000 miles.................................................................................................................................................................. 335 11.1.14 Service at 65,000 miles.................................................................................................................................................................. 336 11.1.15 Service at 70,000 miles.................................................................................................................................................................. 336 11.1.16 Service at 75,000 miles.................................................................................................................................................................. 336 11.1.17 Service at 80,000 miles.................................................................................................................................................................. 336 11.1.18 Service at 85,000 miles.................................................................................................................................................................. 337 11.1.19 Service at 90,000 miles.................................................................................................................................................................. 337 11.1.20 Service at 95,000 miles.................................................................................................................................................................. 338 11.1.21 Service at 100,000 miles................................................................................................................................................................. 338 11.1.22 Service at 105,000 miles................................................................................................................................................................. 339 11.2 MY 2005 Maintenance Intervals - Canada.......................................................................................................................................................... 340 11.2.1 Time-Dependent Maintenance Items.......................................................................................................................................................... 340 11.2.2 Service at 8,000 kilometers............................................................................................................................................................... 341 11.2.3 Service at 16,000 kilometers.............................................................................................................................................................. 341 11.2.4 Service at 24,000 kilometers.............................................................................................................................................................. 341 11.2.5 Service at 32,000 kilometers.............................................................................................................................................................. 341 11.2.6 Service at 40,000 kilometers.............................................................................................................................................................. 342 11.2.7 Service at 48,000 kilometers.............................................................................................................................................................. 342 11.2.8 Service at 56,000 kilometers.............................................................................................................................................................. 342 11.2.9 Service at 64,000 kilometers.............................................................................................................................................................. 343 11.2.10 Service at 72,000 kilometers............................................................................................................................................................. 344 11.2.11 Service at 80,000 kilometers............................................................................................................................................................. 344 11.2.12 Service at 88,000 kilometers............................................................................................................................................................. 344 11.2.13 Service at 96,000 kilometers............................................................................................................................................................. 344 11.2.14 Service at 104,000 kilometers............................................................................................................................................................ 345 11.2.15 Service at 112,000 kilometers............................................................................................................................................................ 345 11.2.16 Service at 120,000 kilometers............................................................................................................................................................ 346 11.2.17 Service at 128,000 kilometers............................................................................................................................................................ 346 11.2.18 Service at 136,000 kilometers............................................................................................................................................................ 347 11.2.19 Service at 144,000 kilometers............................................................................................................................................................ 347 11.2.20 Service at 152,000 kilometers............................................................................................................................................................ 347 11.2.21 Service at 160,000 kilometers............................................................................................................................................................ 348 11.2.22 Service at 168,000 kilometers............................................................................................................................................................ 349 12 MY 2004 Maintenance Intervals......................................................................................................................................................................... 350 12.1 MY 2004 Maintenance Intervals - USA............................................................................................................................................................. 350 12.1.1 Time-Dependent Maintenance Items.......................................................................................................................................................... 350 12.1.2 Service at 5,000 miles.................................................................................................................................................................... 351 12.1.3 Service at 10,000 miles................................................................................................................................................................... 351 12.1.4 Service at 15,000 miles................................................................................................................................................................... 351 12.1.5 Service at 20,000 miles................................................................................................................................................................... 351 12.1.6 Service at 25,000 miles................................................................................................................................................................... 352 12.1.7 Service at 30,000 miles................................................................................................................................................................... 352 12.1.8 Service at 35,000 miles................................................................................................................................................................... 352 12.1.9 Service at 40,000 miles................................................................................................................................................................... 352 12.1.10 Service at 45,000 miles.................................................................................................................................................................. 353 12.1.11 Service at 50,000 miles.................................................................................................................................................................. 353 12.1.12 Service at 55,000 miles.................................................................................................................................................................. 354 12.1.13 Service at 60,000 miles.................................................................................................................................................................. 354 12.1.14 Service at 65,000 miles.................................................................................................................................................................. 355 12.1.15 Service at 70,000 miles.................................................................................................................................................................. 355 12.1.16 Service at 75,000 miles.................................................................................................................................................................. 355 12.1.17 Service at 80,000 miles.................................................................................................................................................................. 355 12.1.18 Service at 85,000 miles.................................................................................................................................................................. 356 12.1.19 Service at 90,000 miles.................................................................................................................................................................. 356 12.1.20 Service at 95,000 miles.................................................................................................................................................................. 357 12.1.21 Service at 100,000 miles................................................................................................................................................................. 357 12.1.22 Service at 105,000 miles................................................................................................................................................................. 357 12.2 MY 2004 Maintenance Intervals - Canada.......................................................................................................................................................... 358 12.2.1 Time-Dependent Maintenance Items.......................................................................................................................................................... 358 12.2.2 Service at 8,000 kilometers............................................................................................................................................................... 359 12.2.3 Service at 16,000 kilometers.............................................................................................................................................................. 359 12.2.4 Service at 24,000 kilometers.............................................................................................................................................................. 359 12.2.5 Service at 32,000 kilometers.............................................................................................................................................................. 359 12.2.6 Service at 40,000 kilometers.............................................................................................................................................................. 360 12.2.7 Service at 48,000 kilometers.............................................................................................................................................................. 360 12.2.8 Service at 56,000 kilometers.............................................................................................................................................................. 360 12.2.9 Service at 64,000 kilometers.............................................................................................................................................................. 360 12.2.10 Service at 72,000 kilometers............................................................................................................................................................. 361 12.2.11 Service at 80,000 kilometers............................................................................................................................................................. 361 12.2.12 Service at 88,000 kilometers............................................................................................................................................................. 362 12.2.13 Service at 96,000 kilometers............................................................................................................................................................. 362 12.2.14 Service at 104,000 kilometers............................................................................................................................................................ 362 12.2.15 Service at 112,000 kilometers............................................................................................................................................................ 362 12.2.16 Service at 120,000 kilometers............................................................................................................................................................ 363 12.2.17 Service at 128,000 kilometers............................................................................................................................................................ 363 12.2.18 Service at 136,000 kilometers............................................................................................................................................................ 364 12.2.19 Service at 144,000 kilometers............................................................................................................................................................ 364 12.2.20 Service at 152,000 kilometers............................................................................................................................................................ 364 12.2.21 Service at 160,000 kilometers............................................................................................................................................................ 364 12.2.22 Service at 168,000 kilometers............................................................................................................................................................ 365 13 MY 2003 Maintenance Intervals......................................................................................................................................................................... 366 13.1 MY 2003 Maintenance Intervals - USA............................................................................................................................................................. 366 13.1.1 Time-Dependent Maintenance Items.......................................................................................................................................................... 366 13.1.2 Service at 5,000 miles.................................................................................................................................................................... 366 13.1.3 Service at 10,000 miles................................................................................................................................................................... 367 13.1.4 Service at 15,000 miles................................................................................................................................................................... 367 13.1.5 Service at 20,000 miles................................................................................................................................................................... 367 13.1.6 Service at 25,000 miles................................................................................................................................................................... 368 13.1.7 Service at 30,000 miles................................................................................................................................................................... 368 13.1.8 Service at 35,000 miles................................................................................................................................................................... 368 13.1.9 Service at 40,000 miles................................................................................................................................................................... 368 13.1.10 Service at 45,000 miles.................................................................................................................................................................. 369 13.1.11 Service at 50,000 miles.................................................................................................................................................................. 369 13.1.12 Service at 55,000 miles.................................................................................................................................................................. 369 13.1.13 Service at 60,000 miles.................................................................................................................................................................. 369 13.1.14 Service at 65,000 miles.................................................................................................................................................................. 370 13.1.15 Service at 70,000 miles.................................................................................................................................................................. 370 13.1.16 Service at 75,000 miles.................................................................................................................................................................. 370 13.1.17 Service at 80,000 miles.................................................................................................................................................................. 370 13.1.18 Service at 85,000 miles.................................................................................................................................................................. 371 13.1.19 Service at 90,000 miles.................................................................................................................................................................. 371 13.1.20 Service at 95,000 miles.................................................................................................................................................................. 372 13.1.21 Service at 100,000 miles................................................................................................................................................................. 372 13.1.22 Service at 105,000 miles................................................................................................................................................................. 372 13.2 MY 2003 Maintenance Intervals - Canada.......................................................................................................................................................... 373 13.2.1 Time-Dependent Maintenance Items.......................................................................................................................................................... 373 13.2.2 Service at 8,000 kilometers............................................................................................................................................................... 373 13.2.3 Service at 16,000 kilometers.............................................................................................................................................................. 373 13.2.4 Service at 24,000 kilometers.............................................................................................................................................................. 374 13.2.5 Service at 32,000 kilometers.............................................................................................................................................................. 374 13.2.6 Service at 40,000 kilometers.............................................................................................................................................................. 374 13.2.7 Service at 48,000 kilometers.............................................................................................................................................................. 374 13.2.8 Service at 56,000 kilometers.............................................................................................................................................................. 375 13.2.9 Service at 64,000 kilometers.............................................................................................................................................................. 375 13.2.10 Service at 72,000 kilometers............................................................................................................................................................. 376 13.2.11 Service at 80,000 kilometers............................................................................................................................................................. 376 13.2.12 Service at 88,000 kilometers............................................................................................................................................................. 376 13.2.13 Service at 96,000 kilometers............................................................................................................................................................. 376 13.2.14 Service at 104,000 kilometers............................................................................................................................................................ 377 13.2.15 Service at 112,000 kilometers............................................................................................................................................................ 377 13.2.16 Service at 120,000 kilometers............................................................................................................................................................ 377 13.2.17 Service at 128,000 kilometers............................................................................................................................................................ 377 13.2.18 Service at 136,000 kilometers............................................................................................................................................................ 378 13.2.19 Service at 144,000 kilometers............................................................................................................................................................ 378 13.2.20 Service at 152,000 kilometers............................................................................................................................................................ 378 13.2.21 Service at 160,000 kilometers............................................................................................................................................................ 378 13.2.22 Service at 168,000 kilometers............................................................................................................................................................ 379 14 MY 2002 Maintenance Intervals......................................................................................................................................................................... 380 14.1 MY 2002 Maintenance Intervals - USA............................................................................................................................................................. 380 14.1.1 Time-Dependent Maintenance Items.......................................................................................................................................................... 380 14.1.2 Service at 5,000 miles.................................................................................................................................................................... 380 14.1.3 Service at 10,000 miles................................................................................................................................................................... 381 14.1.4 Service at 15,000 miles................................................................................................................................................................... 381 14.1.5 Service at 20,000 miles................................................................................................................................................................... 381 14.1.6 Service at 25,000 miles................................................................................................................................................................... 382 14.1.7 Service at 30,000 miles................................................................................................................................................................... 382 14.1.8 Service at 35,000 miles................................................................................................................................................................... 382 14.1.9 Service at 40,000 miles................................................................................................................................................................... 382 14.1.10 Service at 45,000 miles.................................................................................................................................................................. 383 14.1.11 Service at 50,000 miles.................................................................................................................................................................. 383 14.1.12 Service at 55,000 miles.................................................................................................................................................................. 383 14.1.13 Service at 60,000 miles.................................................................................................................................................................. 383 14.1.14 Service at 65,000 miles.................................................................................................................................................................. 384 14.1.15 Service at 70,000 miles.................................................................................................................................................................. 384 14.1.16 Service at 75,000 miles.................................................................................................................................................................. 384 14.1.17 Service at 80,000 miles.................................................................................................................................................................. 384 14.1.18 Service at 85,000 miles.................................................................................................................................................................. 385 14.1.19 Service at 90,000 miles.................................................................................................................................................................. 385 14.1.20 Service at 95,000 miles.................................................................................................................................................................. 386 14.1.21 Service at 100,000 miles................................................................................................................................................................. 386 14.1.22 Service at 105,000 miles................................................................................................................................................................. 386 14.2 MY 2002 Maintenance Intervals - Canada.......................................................................................................................................................... 387 14.2.1 Time-Dependent Maintenance Items.......................................................................................................................................................... 387 14.2.2 Service at 8,000 kilometers............................................................................................................................................................... 387 14.2.3 Service at 16,000 kilometers.............................................................................................................................................................. 387 14.2.4 Service at 24,000 kilometers.............................................................................................................................................................. 388 14.2.5 Service at 32,000 kilometers.............................................................................................................................................................. 388 14.2.6 Service at 40,000 kilometers.............................................................................................................................................................. 388 14.2.7 Service at 48,000 kilometers.............................................................................................................................................................. 388 14.2.8 Service at 56,000 kilometers.............................................................................................................................................................. 389 14.2.9 Service at 64,000 kilometers.............................................................................................................................................................. 389 14.2.10 Service at 72,000 kilometers............................................................................................................................................................. 390 14.2.11 Service at 80,000 kilometers............................................................................................................................................................. 390 14.2.12 Service at 88,000 kilometers............................................................................................................................................................. 390 14.2.13 Service at 96,000 kilometers............................................................................................................................................................. 390 14.2.14 Service at 104,000 kilometers............................................................................................................................................................ 391 14.2.15 Service at 112,000 kilometers............................................................................................................................................................ 391 14.2.16 Service at 120,000 kilometers............................................................................................................................................................ 391 14.2.17 Service at 128,000 kilometers............................................................................................................................................................ 391 14.2.18 Service at 136,000 kilometers............................................................................................................................................................ 392 14.2.19 Service at 144,000 kilometers............................................................................................................................................................ 392 14.2.20 Service at 152,000 kilometers............................................................................................................................................................ 392 14.2.21 Service at 160,000 kilometers............................................................................................................................................................ 392 14.2.22 Service at 168,000 kilometers............................................................................................................................................................ 393 15 MY 2001 Maintenance Intervals......................................................................................................................................................................... 394 15.1 MY 2001 Maintenance Intervals - USA............................................................................................................................................................. 394 15.1.1 Time-Dependent Maintenance Items.......................................................................................................................................................... 394 15.1.2 Service at 5,000 miles.................................................................................................................................................................... 395 15.1.3 Service at 10,000 miles................................................................................................................................................................... 395 15.1.4 Service at 15,000 miles................................................................................................................................................................... 395 15.1.5 Service at 20,000 miles................................................................................................................................................................... 395 15.1.6 Service at 25,000 miles................................................................................................................................................................... 396 15.1.7 Service at 30,000 miles................................................................................................................................................................... 396 15.1.8 Service at 35,000 miles................................................................................................................................................................... 396 15.1.9 Service at 40,000 miles................................................................................................................................................................... 396 15.1.10 Service at 45,000 miles.................................................................................................................................................................. 397 15.1.11 Service at 50,000 miles.................................................................................................................................................................. 397 15.1.12 Service at 55,000 miles.................................................................................................................................................................. 397 15.1.13 Service at 60,000 miles.................................................................................................................................................................. 397 15.1.14 Service at 65,000 miles.................................................................................................................................................................. 398 15.1.15 Service at 70,000 miles.................................................................................................................................................................. 398 15.1.16 Service at 75,000 miles.................................................................................................................................................................. 398 15.1.17 Service at 80,000 miles.................................................................................................................................................................. 398 15.1.18 Service at 85,000 miles.................................................................................................................................................................. 399 15.1.19 Service at 90,000 miles.................................................................................................................................................................. 399 15.1.20 Service at 95,000 miles.................................................................................................................................................................. 399 15.1.21 Service at 100,000 miles................................................................................................................................................................. 399 15.1.22 Service at 105,000 miles................................................................................................................................................................. 400 15.2 MY 2001 Maintenance Intervals - Canada.......................................................................................................................................................... 401 15.2.1 Time-Dependent Maintenance Items.......................................................................................................................................................... 401 15.2.2 Service at 8,000 kilometers............................................................................................................................................................... 401 15.2.3 Service at 16,000 kilometers.............................................................................................................................................................. 401 15.2.4 Service at 24,000 kilometers.............................................................................................................................................................. 402 15.2.5 Service at 32,000 kilometers.............................................................................................................................................................. 402 15.2.6 Service at 40,000 kilometers.............................................................................................................................................................. 402 15.2.7 Service at 48,000 kilometers.............................................................................................................................................................. 402 15.2.8 Service at 56,000 kilometers.............................................................................................................................................................. 403 15.2.9 Service at 64,000 kilometers.............................................................................................................................................................. 403 15.2.10 Service at 72,000 kilometers............................................................................................................................................................. 403 15.2.11 Service at 80,000 kilometers............................................................................................................................................................. 404 15.2.12 Service at 88,000 kilometers............................................................................................................................................................. 404 15.2.13 Service at 96,000 kilometers............................................................................................................................................................. 404 15.2.14 Service at 104,000 kilometers............................................................................................................................................................ 404 15.2.15 Service at 112,000 kilometers............................................................................................................................................................ 405 15.2.16 Service at 120,000 kilometers............................................................................................................................................................ 405 15.2.17 Service at 128,000 kilometers............................................................................................................................................................ 405 15.2.18 Service at 136,000 kilometers............................................................................................................................................................ 406 15.2.19 Service at 144,000 kilometers............................................................................................................................................................ 406 15.2.20 Service at 152,000 kilometers............................................................................................................................................................ 406 15.2.21 Service at 160,000 kilometers............................................................................................................................................................ 406 15.2.22 Service at 168,000 kilometers............................................................................................................................................................ 407 16 MY 2000 Maintenance Intervals......................................................................................................................................................................... 408 16.1 MY 2000 Maintenance Intervals - USA............................................................................................................................................................. 408 16.1.1 Time-Dependent Maintenance Items.......................................................................................................................................................... 408 16.1.2 Service at 5,000 miles.................................................................................................................................................................... 408 16.1.3 Service at 10,000 miles................................................................................................................................................................... 409 16.1.4 Service at 15,000 miles................................................................................................................................................................... 409 16.1.5 Service at 20,000 miles................................................................................................................................................................... 409 16.1.6 Service at 25,000 miles................................................................................................................................................................... 410 16.1.7 Service at 30,000 miles................................................................................................................................................................... 410 16.1.8 Service at 35,000 miles................................................................................................................................................................... 410 16.1.9 Service at 40,000 miles................................................................................................................................................................... 410 16.1.10 Service at 45,000 miles.................................................................................................................................................................. 411 16.1.11 Service at 50,000 miles.................................................................................................................................................................. 411 16.1.12 Service at 55,000 miles.................................................................................................................................................................. 411 16.1.13 Service at 60,000 miles.................................................................................................................................................................. 411 16.1.14 Service at 65,000 miles.................................................................................................................................................................. 412 16.1.15 Service at 70,000 miles.................................................................................................................................................................. 412 16.1.16 Service at 75,000 miles.................................................................................................................................................................. 412 16.1.17 Service at 80,000 miles.................................................................................................................................................................. 412 16.1.18 Service at 85,000 miles.................................................................................................................................................................. 413 16.1.19 Service at 90,000 miles.................................................................................................................................................................. 413 16.1.20 Service at 95,000 miles.................................................................................................................................................................. 413 16.1.21 Service at 100,000 miles................................................................................................................................................................. 413 16.1.22 Service at 105,000 miles................................................................................................................................................................. 414 16.2 MY 2000 Maintenance Intervals - Canada.......................................................................................................................................................... 415 16.2.1 Time-Dependent Maintenance Items.......................................................................................................................................................... 415 16.2.2 Service at 8,000 kilometers............................................................................................................................................................... 415 16.2.3 Service at 16,000 kilometers.............................................................................................................................................................. 415 16.2.4 Service at 24,000 kilometers.............................................................................................................................................................. 416 16.2.5 Service at 32,000 kilometers.............................................................................................................................................................. 416 16.2.6 Service at 40,000 kilometers.............................................................................................................................................................. 416 16.2.7 Service at 48,000 kilometers.............................................................................................................................................................. 416 16.2.8 Service at 56,000 kilometers.............................................................................................................................................................. 417 16.2.9 Service at 64,000 kilometers.............................................................................................................................................................. 417 16.2.10 Service at 72,000 kilometers............................................................................................................................................................. 417 16.2.11 Service at 80,000 kilometers............................................................................................................................................................. 418 16.2.12 Service at 88,000 kilometers............................................................................................................................................................. 418 16.2.13 Service at 96,000 kilometers............................................................................................................................................................. 418 16.2.14 Service at 104,000 kilometers............................................................................................................................................................ 418 16.2.15 Service at 112,000 kilometers............................................................................................................................................................ 419 16.2.16 Service at 120,000 kilometers............................................................................................................................................................ 419 16.2.17 Service at 128,000 kilometers............................................................................................................................................................ 419 16.2.18 Service at 136,000 kilometers............................................................................................................................................................ 420 16.2.19 Service at 144,000 kilometers............................................................................................................................................................ 420 16.2.20 Service at 152,000 kilometers............................................................................................................................................................ 420 16.2.21 Service at 160,000 kilometers............................................................................................................................................................ 420 16.2.22 Service at 168,000 kilometers............................................................................................................................................................ 421 00-03 Maintenance................................................................................................................................................................................................ 425 1 Overview - Engine.......................................................................................................................................................................................... 431 2 Service Work............................................................................................................................................................................................... 433 2.1 Fixed Service Information............................................................................................................................................................................ 433 2.1.1 Service Identification......................................................................................................................................................................... 433 2.1.2 Flexible Service............................................................................................................................................................................... 433 2.1.3 Fixed Service.................................................................................................................................................................................. 434 2.1.4 Service Interval Display....................................................................................................................................................................... 434 2.2 Maintenance Tables for Market Designation A.......................................................................................................................................................... 435 2.2.1 Maintenance Tables for Market Designation A.................................................................................................................................................... 435 2.3 Maintenance Tables for Market Designation B and C.................................................................................................................................................... 436 2.3.1 Delivery Inspection............................................................................................................................................................................ 436 2.3.2 Services....................................................................................................................................................................................... 437 2.3.3 Time and Distance-Dependent Additional Work, from MY 2013...................................................................................................................................... 440 3 General Information........................................................................................................................................................................................ 442 3.1 High-Voltage System General Warnings................................................................................................................................................................. 442 3.2 Vehicle, Raising with Hoist or Workshop Vehicle Jack................................................................................................................................................. 442 3.2.1 Safety Precautions............................................................................................................................................................................. 442 3.2.2 Hoist and Floor Jack Mounting Points........................................................................................................................................................... 443 3.3 Label................................................................................................................................................................................................ 444 3.4 Maintenance Schedule Entries......................................................................................................................................................................... 444 3.5 Vehicle Diagnostic Tester............................................................................................................................................................................ 444 3.5.1 Vehicle Diagnostic Tester, Connecting.......................................................................................................................................................... 444 3.6 Vehicle Identification Number (VIN).................................................................................................................................................................. 445 3.6.2 VIN on Longitudinal Member Extension........................................................................................................................................................... 446 3.6.3 VIN Decoding................................................................................................................................................................................... 446 3.7 Vehicle Data Label................................................................................................................................................................................... 446 3.8 Severe Operating Conditions.......................................................................................................................................................................... 447 3.9 Country Assignment According to Market Designation................................................................................................................................................... 447 3.10 Engine Code and Engine Number....................................................................................................................................................................... 447 3.11 Countries with High Air Dust Levels................................................................................................................................................................. 447 3.12 Type Plate.......................................................................................................................................................................................... 448 4 Procedure Descriptions..................................................................................................................................................................................... 451 4.1 Ball Joints and Axle Bearing, Visually Inspecting.................................................................................................................................................... 453 4.2 Automatic Headlamp Control and Stationary Cornering Lamp, Checking Function.......................................................................................................................... 454 4.3 Automatic Transmission 09G, Changing ATF............................................................................................................................................................. 455 4.4 Font Passenger Airbag, Checking Key Switch and “ON/OFF Function”..................................................................................................................................... 455 4.5 12V Battery, Checking Battery Terminal Clamp for Secure Seating...................................................................................................................................... 457 4.5.1 12V Engine Compartment Battery, Checking Battery Terminal Clamp for Secure Seating............................................................................................................. 457 4.5.2 12V Luggage Compartment Battery, Checking Battery Terminal Clamp for Secure Seating............................................................................................................ 458 4.6 12V Battery, Checking Using Battery Tester (Always Follow Repair Manual)............................................................................................................................. 461 4.7 12V Battery Level, Reading and Sending Diagnostic Log Online......................................................................................................................................... 461 4.8 Tires, Checking Condition, Wear Pattern, Pressure and Tread Depth.................................................................................................................................... 461 4.8.1 Tires, Checking Condition...................................................................................................................................................................... 462 4.8.2 Tires, Checking Wear Pattern................................................................................................................................................................... 462 4.8.4 General Information............................................................................................................................................................................ 463 4.8.5 Tire Pressures, Golf/e-Golf.................................................................................................................................................................... 464 4.8.6 Tire Pressures, Golf Wagon..................................................................................................................................................................... 485 4.8.7 Tire Pressures, Golf Sportsvan................................................................................................................................................................. 495 4.9 Brake and Clutch System, Changing Brake Fluid........................................................................................................................................................ 498 4.10 Brake System and Shock Absorbers, Visually Inspecting for Leaks and Damage.......................................................................................................................... 502 4.11 Front and Rear Brake Rotors, Checking Brake Pad Thickness and Condition............................................................................................................................. 503 4.11.1 Front Disc Brake Pads......................................................................................................................................................................... 503 4.11.2 Rear Disc Brake Pads.......................................................................................................................................................................... 504 4.11.3 Brake Rotors, Checking........................................................................................................................................................................ 504 4.12 Brake Fluid Level, Checking......................................................................................................................................................................... 505 4.13 6-Speed Direct Shift Gearbox (DSG®) Transmission 0D9, Changing Transmission Fluid and Filter........................................................................................................ 506 4.14 6-Speed Direct Shift Gearbox (DSG®) Transmission 0DD, Changing Transmission Fluid................................................................................................................... 506 4.15 Diesel Parcticulate Filter, Checking................................................................................................................................................................ 506 4.16 Three-Phrase Current Drive, Calibrating............................................................................................................................................................. 507 4.17 Power Window Regulators, Checking Position.......................................................................................................................................................... 507 4.18 Natural Gas System, Visually Inspecting Natural Gas Fuel Tank for Corrosion, Performing Leak Test................................................................................................... 508 4.19 Natural Gas Tank, Replacing......................................................................................................................................................................... 512 4.20 Natural Gas Filler Tube and Cap, Checking Condition, Cleaning and Checking the Seal if Necessary.................................................................................................... 512 4.21 DTC Memory for All Systems, Reading with Vehicle Diagnostic Tester and Correcting Faults According to Repair Procedure.............................................................................. 513 4.22 Overview - Driving School Pedals.................................................................................................................................................................... 514 4.22.1 Overview - Driving School Pedals, Driver Side, Golf Sedan..................................................................................................................................... 514 4.22.2 Overview - Driving School Pedals, Front Passenger Side, Golf Sedan............................................................................................................................ 515 4.22.3 Overview - Driving School Pedals, Driver Side, Manual Transmission, Golf Sportsvan............................................................................................................ 516 4.22.4 Overview - Driving School Pedals, Driver Side, Automatic Transmission, Golf Sportsvan......................................................................................................... 517 4.22.5 Overview - Driving School Pedals, Front Passenger Side, Golf Sportsvan........................................................................................................................ 518 4.23 Driving School Pedals, Lubricating Components....................................................................................................................................................... 519 4.23.1 General Information........................................................................................................................................................................... 519 4.23.2 Brake Carrier Slot Lever, Lubricating, Driver Side Driving School Pedals...................................................................................................................... 519 4.23.3 Accelerator Pedal Carrier Slot Lever, Lubricating, Driver Side Driving School Pedals.......................................................................................................... 520 4.23.4 Brake Transfer Push Rod Joint, Lubricating, Driver Side Driving School Pedals................................................................................................................. 520 4.23.5 Right Shaft Bearing, Lubricating, Driver Side Driving School Pedals........................................................................................................................... 521 4.23.6 Left Shaft Bearing, Lubricating, Driver Side Driving School Pedals............................................................................................................................ 521 4.23.7 Left Shaft Bearing, Lubricating, Front Passenger Side Driving School Pedals................................................................................................................... 522 4.23.8 Right Shaft Bearing, Lubricating, Front Passenger Side Driving School Pedals.................................................................................................................. 522 4.23.9 Clutch Pedal Carrier, Lubricating, Driver Side Driving School Pedals.......................................................................................................................... 522 4.23.10 Clutch Pedal Shaft Bearing, Lubricating, Driver Side Driving School Pedals................................................................................................................... 523 4.24 Driving School Pedals, Checking for Secure Bolt Fit................................................................................................................................................. 523 4.24.1 General Information........................................................................................................................................................................... 523 4.24.2 Threaded Connection on Brake Carrier, Checking for Secure Fit, Driver Side Driving School Pedals.............................................................................................. 524 4.24.3 Threaded Connection on Shaft Bearing Mounting Bracket, Checking for Secure Fit, Front Passenger Side Driving School Pedals.................................................................... 524 4.24.4 Right Wing Nut on the Throttle Shaft, Checking for Secure Seating, Front Passenger Side Driving School Pedals................................................................................. 525 4.25 Overview - Control Equipment Buzzer................................................................................................................................................................. 525 4.25.1 Overview - Control Equipment Buzzer, Golf Sedan............................................................................................................................................... 525 4.25.2 Overview - Control Equipment Buzzer, Golf Sportsvan........................................................................................................................................... 527 4.26 Driving School Pedals, Adjusting Activation Timing for Control Equipment Warning Buzzer............................................................................................................. 527 4.27 CV Boots, Visually Inspecting....................................................................................................................................................................... 528 4.28 Haldex Clutch, Changing Oil......................................................................................................................................................................... 529 4.29 High-Voltage Battery Charge Level, Checking......................................................................................................................................................... 532 4.30 High-Voltage Battery Maintenance.................................................................................................................................................................... 533 4.31 High-Voltage Battery, Charging...................................................................................................................................................................... 533 4.32 High-Voltage Components and High-Voltage Cables, Visually Inspecting for Damage, Correct Wire Routing and Attachment................................................................................ 533 4.33 Hybrid Components, Visually Inspecting for Damage of the High-Voltage Components and Wires.......................................................................................................... 534 4.34 Interior and Exterior Body, Visually Inspecting for Corrosion with Doors and Lids Opened............................................................................................................ 535 4.35 Ribbed Belt, Checking Condition..................................................................................................................................................................... 535 4.36 Cooling System, Checking Freeze Protection and Coolant Level........................................................................................................................................ 537 4.36.1 Freeze Protection, Checking and Adding Coolant Additive if Necessary.......................................................................................................................... 537 4.36.2 Coolant Level, Checking and Filling if Necessary.............................................................................................................................................. 538 4.36.3 Mixture Ratio................................................................................................................................................................................. 539 4.37 High-Voltage Cooling System, Checking Freeze Protection and Coolant Level........................................................................................................................... 540 4.37.1 Coolant Level, Checking and Filling if Necessary.............................................................................................................................................. 540 4.37.2 Freeze Protection, Checking and Adding Coolant Additive if Necessary.......................................................................................................................... 542 4.37.3 Mixture Ratio................................................................................................................................................................................. 542 4.38 Diesel Fuel Filter, Draining Water.................................................................................................................................................................. 543 4.39 Diesel Fuel Filter, Replacing....................................................................................................................................................................... 544 4.40 Air Filter, Cleaning Housing and Replacing Filter Element........................................................................................................................................... 546 4.40.1 Air Filter Element, Removing and Installing, 1.4L TSI Engines................................................................................................................................. 547 4.40.2 Air Filter Element, Removing and Installing, 2.0L TSI Engine.................................................................................................................................. 549 4.40.3 Air Filter Element, Removing and Installing, Common Rail Engines.............................................................................................................................. 551 4.40.4 Air Filter Housing, Cleaning.................................................................................................................................................................. 552 4.40.5 Air Filter Element, Removing and Installing, 1.0L TSI Engines................................................................................................................................. 552 4.40.6 Air Filter Element, Removing and Installing, 1.6L SRE Engine.................................................................................................................................. 555 4.41 Multipurpose Additive for Gasoline, Adding.......................................................................................................................................................... 555 4.42 Engine and Engine Compartment Components, Visually Inspecting for Leaks and Damage (from Above and Below)........................................................................................... 556 4.43 “Upper” Engine Cover, Removing and Installing....................................................................................................................................................... 557 4.43.1 Engine Cover, Removing and Installing, 1.4L TSI Hybrid Engine................................................................................................................................. 557 4.43.2 Engine Cover, Removing and Installing, 2.0L TSI Engine........................................................................................................................................ 557 4.43.3 Engine Cover, Removing and Installing, Common Rail Diesel Engines............................................................................................................................. 557 4.44 “Lower” Engine Compartment Cover (Noise Insulation), Removing and Installing........................................................................................................................ 558 4.45 Engine Oil Level, Checking.......................................................................................................................................................................... 558 4.46 Engine Oil, Draining, Replacing Oil Filter, and Filling............................................................................................................................................. 559 4.46.1 Information for Engines with Turbochargers.................................................................................................................................................... 559 4.46.2 Engine Oil, Draining and Replacing Oil Filter, 1.4L TSI Engines............................................................................................................................... 560 4.46.3 Engine Oil, Draining and Replacing Oil Filter, Common Rail Diesel Engines..................................................................................................................... 562 4.46.4 Engine Oil, Draining and Replacing Oil Filter, 2.0L TSI Engine................................................................................................................................ 565 4.46.5 Engine Oil, Draining and Replacing Oil Filter, 2.0L TSI Engine, “R Model”..................................................................................................................... 567 4.46.6 Engine Oil, Filling........................................................................................................................................................................... 571 4.47 Engine Oil, Capacities and Specifications........................................................................................................................................................... 571 4.47.1 Golf.......................................................................................................................................................................................... 571 4.47.2 Golf Wagon.................................................................................................................................................................................... 571 4.47.3 Sportsvan..................................................................................................................................................................................... 571 4.48 Panorama Sliding Sunroof, Checking Function, Cleaning and Greasing Guide Rails, Cleaning Wind Deflector............................................................................................. 572 4.48.1 Checking Function, Cleaning and Greasing Guide Rails.......................................................................................................................................... 572 4.48.2 Wind Deflector, Cleaning...................................................................................................................................................................... 574 4.49 Panorama Sliding/Tilting Sunroof with Rear Panorama Roof, Checking Function, Cleaning and Greasing Guide Rails, and Cleaning Wind Deflector......................................................... 574 4.49.1 Checking Function, Cleaning and Greasing Guide Rails.......................................................................................................................................... 574 4.49.2 Wind Deflector, Cleaning...................................................................................................................................................................... 575 4.50 Road Test, Performing (Driving Behavior, Noises, A/C System, etc.).................................................................................................................................. 576 4.51 Wheel Bolts, Tightening to Specification............................................................................................................................................................ 576 4.52 Tire Pressure Monitoring System, Calibrating........................................................................................................................................................ 579 4.53 Tire Repair Kit, Checking........................................................................................................................................................................... 580 4.54 Windshield Wiper and Washer System and Headlamp Washer System, Checking Function.................................................................................................................... 581 4.54.1 Freeze Protection Fluid Contents, Checking and Filling if Necessary........................................................................................................................... 581 4.54.2 Windshield Wiper/Washer System, Checking Spray Nozzle Adjustment and Adjusting, if Necessary.................................................................................................. 582 4.54.3 Headlamp Washer System, Checking Washer Nozzle Adjustment..................................................................................................................................... 584 4.54.4 Windshield Wiper Blades, Checking Park Position............................................................................................................................................... 584 4.54.5 Rear Wiper Blade, Checking Park Position...................................................................................................................................................... 584 4.55 Windshield Wiper Protectors, Removing............................................................................................................................................................... 584 4.55.1 Windshield Wiper Protectors, Removing, Version 1.............................................................................................................................................. 585 4.55.2 Windshield Wiper Protectors, Removing, Version 2.............................................................................................................................................. 586 4.55.3 Windshield Wiper Protectors, Replacing Version 3 “Transport Wiper Blade”...................................................................................................................... 587 4.56 Headlamp Adjustment, Checking, Halogen Headlamp..................................................................................................................................................... 587 4.56.1 Checking and Adjusting Conditions............................................................................................................................................................. 587 4.56.2 Headlamp Adjustment, Checking (SAE)........................................................................................................................................................... 588 4.56.3 Halogen Headlamps, Adjusting.................................................................................................................................................................. 589 4.56.4 Headlamp Adjustment, Checking (ECE)........................................................................................................................................................... 590 4.57 Headlamp Adjustment, Checking, HID Headlamp without Dynamic Light Assist............................................................................................................................ 591 4.57.1 Checking and Adjusting Conditions............................................................................................................................................................. 591 4.57.2 Headlamp Adjustment, Checking (SAE)........................................................................................................................................................... 592 4.57.3 HID Headlamps without “Dynamic Light Assist”, Adjusting....................................................................................................................................... 593 4.57.4 Headlamp Adjustment, Checking (ECE)........................................................................................................................................................... 594 4.58 Headlamp Adjustment, Checking, HID Headlamp with Dynamic Light Assist............................................................................................................................... 595 4.58.1 Checking and Adjusting Conditions............................................................................................................................................................. 595 4.58.2 Headlamp Adjustment, Checking (SAE)........................................................................................................................................................... 596 4.58.3 HID Headlamps with “Dynamic Light Assist”, Adjusting.......................................................................................................................................... 599 4.58.4 Headlamp Adjustment, Checking (ECE)........................................................................................................................................................... 600 4.59 Headlamp Adjustment, Checking, LED Headlamps........................................................................................................................................................ 602 4.59.1 Checking and Adjusting Conditions............................................................................................................................................................. 602 4.59.2 Headlamp Adjustment, Checking (ECE)........................................................................................................................................................... 602 4.59.3 Headlamp Adjustment, Checking (SAE)........................................................................................................................................................... 603 4.59.4 LED Headlamps: Adjusting...................................................................................................................................................................... 604 4.60 Headlamp Adjustment, Checking, Fog Lamp............................................................................................................................................................. 606 4.60.1 Checking and Adjusting Conditions............................................................................................................................................................. 606 4.60.2 Headlamps, Checking Adjustment................................................................................................................................................................ 606 4.60.3 Fog Lamps and Other Auxiliary Headlamps, Adjusting............................................................................................................................................ 607 4.61 Service Interval Display, Resetting................................................................................................................................................................. 608 4.61.1 Service Interval Display, Resetting with Vehicle Diagnostic Tester............................................................................................................................ 608 4.61.2 Service Interval Display, Resetting without Vehicle Diagnosis Tester.......................................................................................................................... 609 4.62 Service Interval Display, Coding.................................................................................................................................................................... 609 4.63 Tie Rod Ends, Checking Play, Attachment and Ball Joint Boots........................................................................................................................................ 610 4.64 Dust and Pollen Filter, Cleaning Housing and Replacing Filter....................................................................................................................................... 611 4.65 Battery Transport Mode, Deactivating................................................................................................................................................................ 611 4.66 Transportation Safeguards, Removing Transportation Blocks........................................................................................................................................... 612 4.67 Clock and Date, Adjusting........................................................................................................................................................................... 613 4.68 Underbody, Visually Inspecting Underbody Protection, Underbody Trim Panels, Wire Routing and Plugs for Damage....................................................................................... 614 4.69 Front Axle Differential Lock, Changing Oil.......................................................................................................................................................... 614 4.69.1 Front Axle Differential Lock, Changing Oil, “R Model”......................................................................................................................................... 618 4.70 e-Golf Warning Label, Checking...................................................................................................................................................................... 622 4.70.1 Warning Label, Version 1...................................................................................................................................................................... 622 4.70.2 Warning Label, Version 2...................................................................................................................................................................... 625 4.71 Warning Label, Checking, Golf GTE................................................................................................................................................................... 628 4.72 Camshaft Drive Toothed Belt, Replacing, Diesel Engines.............................................................................................................................................. 631 4.73 Camshaft Drive Toothed Belt, Checking............................................................................................................................................................... 632 4.73.1 Toothed Belt Condition, Checking, 1.4L TSI Engines............................................................................................................................................ 632 4.73.2 Toothed Belt Condition, Checking, 1.0L TSI Engines............................................................................................................................................ 633 4.74 Coolant Pump Toothed Belt, Checking................................................................................................................................................................. 634 4.74.1 Toothed Belt Condition, Checking, 1.4L TSI Engines............................................................................................................................................ 634 4.74.2 Toothed Belt Condition, Checking, 1.0L TSI Engines............................................................................................................................................ 635 4.74.3 Toothed Belt Condition, Checking, 1.6L SRE Engines............................................................................................................................................ 637 4.75 Spark Plugs, Replacing.............................................................................................................................................................................. 638 4.75.1 Spark Plugs, Replacing, 1.4L TSI Engines...................................................................................................................................................... 639 4.75.2 Spark Plugs, Replacing, 2.0L TSI Engine....................................................................................................................................................... 641 4.75.3 Spark Plugs, Replacing, 1.0L TSI Engine....................................................................................................................................................... 643 4.75.4 Spark Plugs, Replacing, 1.6L SRE Engine....................................................................................................................................................... 645 4.75.5 Spark Plugs, Replacing, 1.4L TSI Engine, Engine Codes CPTA and CZEA........................................................................................................................... 647 5 Emissions Test............................................................................................................................................................................................. 651 5.1 Emissions Testing, Gasoline Engines.................................................................................................................................................................. 651 5.2 Emissions Testing, Diesel Engines.................................................................................................................................................................... 659 6 Glossary................................................................................................................................................................................................... 671 00-04 Maintenance Procedures..................................................................................................................................................................................... 677 03 – Maintenance, Diagnosis.................................................................................................................................................................................. 681 1 Note................................................................................................................................................................................................... 681 2 Revision History....................................................................................................................................................................................... 682 00-05 Towing_Guide............................................................................................................................................................................................... 686 00 – General, Technical Data................................................................................................................................................................................. 692 1 Foreword............................................................................................................................................................................................... 692 1.1 Legal Requirements outside Germany............................................................................................................................................................... 692 2 Technical Requirements................................................................................................................................................................................. 693 2.1 Factory-Installed Trailer Hitch.................................................................................................................................................................. 693 2.2 Retrofitted Trailer Hitch........................................................................................................................................................................ 693 2.3 Ball Head........................................................................................................................................................................................ 693 2.4 Trailer Socket................................................................................................................................................................................... 693 2.4.1 »7-Pin« Trailer Socket..................................................................................................................................................................... 694 2.4.2 »13-Pin« Trailer Socket.................................................................................................................................................................... 694 2.5 Towing Recognition Control Module -J345-......................................................................................................................................................... 694 2.5.1 Towing Recognition Control Module -J345-, Retrofitting..................................................................................................................................... 695 2.5.2 Towing Recognition Control Module -J345-, Coding........................................................................................................................................... 695 2.6 Engine Cooling................................................................................................................................................................................... 695 2.7 Exterior Rearview Mirror......................................................................................................................................................................... 696 2.8 Reinforced Shock Absorbers and Coil Springs...................................................................................................................................................... 696 3 Operating and Driving Tips............................................................................................................................................................................. 697 4 General Information.................................................................................................................................................................................... 698 4.1 Trailer Hitch Type Label......................................................................................................................................................................... 698 4.2 Combined Weight.................................................................................................................................................................................. 698 4.3 Trip Recorder.................................................................................................................................................................................... 698 5 Tongue Weight Specifications........................................................................................................................................................................... 699 6 Legal Requirements..................................................................................................................................................................................... 700 7 Beetle from MY 2012.................................................................................................................................................................................... 701 8 Bora from MY 1999 and Bora Wagon from MY 1999.......................................................................................................................................................... 702 9 Eos from MY 2006....................................................................................................................................................................................... 704 10 Fox from MY 2004...................................................................................................................................................................................... 705 11 Golf from MY 1992 and Golf Wagon from MY 1994......................................................................................................................................................... 706 12 Golf Cabrio from MY 1994.............................................................................................................................................................................. 708 13 Golf from MY 1998 and Golf Wagon from MY 1999......................................................................................................................................................... 709 13.1 Golf R32........................................................................................................................................................................................ 710 13.2 Jubilee GTI..................................................................................................................................................................................... 710 13.3 Golf Bifuel..................................................................................................................................................................................... 711 14 Golf from MY 2004..................................................................................................................................................................................... 712 15 Golf Plus from MY 2005................................................................................................................................................................................ 714 16 Golf Wagon from MY 2007............................................................................................................................................................................... 716 17 Golf from MY 2009..................................................................................................................................................................................... 717 18 Golf Plus from MY 09.................................................................................................................................................................................. 719 19 CrossGolf from MY 2009................................................................................................................................................................................ 721 20 Golf Wagon from MY 10................................................................................................................................................................................. 722 21 Golf Convertible from MY 2012......................................................................................................................................................................... 723 22 Golf from MY 13....................................................................................................................................................................................... 724 23 Golf Wagon from MY 2014............................................................................................................................................................................... 727 24 e-Golf from MY 2014................................................................................................................................................................................... 729 25 Golf Sportsvan from MY 2015........................................................................................................................................................................... 730 26 Jetta from MY 2005.................................................................................................................................................................................... 732 27 Jetta from MY 11...................................................................................................................................................................................... 734 28 Jetta from 2015....................................................................................................................................................................................... 736 29 Lupo 3L, Lupo FSI and Lupo GTI from MY 1999........................................................................................................................................................... 738 30 Lupo from MY 1999..................................................................................................................................................................................... 739 31 New Beetle from MY 1999............................................................................................................................................................................... 740 32 New Beetle RSi........................................................................................................................................................................................ 742 33 New Beetle Convertible from MY 2003................................................................................................................................................................... 743 34 Passat Sedan and Wagon from MY 1994................................................................................................................................................................... 744 34.1 Passat Syncro................................................................................................................................................................................... 745 34.1.1 Increasing Towing Weight.................................................................................................................................................................. 746 35 Passat Sedan and Wagon from MY 97..................................................................................................................................................................... 747 36 Passat Sedan and Wagon from MY 2001................................................................................................................................................................... 748 37 Passat W8 from MY 2002................................................................................................................................................................................ 749 38 Passat Sedan from MY 2006............................................................................................................................................................................. 750 39 Passat Wagon from MY 2006............................................................................................................................................................................. 752 40 Passat CC from MY 2009; CC from MY 2010; CC from MY 2012.............................................................................................................................................. 754 41 Passat Sedan from MY 11............................................................................................................................................................................... 757 42 Passat Wagon from MY 2011 and Passat Alltrack from MY 2012............................................................................................................................................ 759 43 Passat Sedan, From MY 2015............................................................................................................................................................................ 761 44 Passat Wagon, From MY 2015............................................................................................................................................................................ 763 45 Phaeton from MY 2003.................................................................................................................................................................................. 765 46 Polo from MY 1995..................................................................................................................................................................................... 766 47 Polo Classic from MY 1996............................................................................................................................................................................. 767 48 Polo Wagon from MY 1998............................................................................................................................................................................... 768 49 Polo from MY 02....................................................................................................................................................................................... 769 50 Polo Fun from MY 2004................................................................................................................................................................................. 771 50.1 Trailer Hitch, Retrofitting..................................................................................................................................................................... 771 51 Polo Sedan from MY 2004............................................................................................................................................................................... 772 52 Polo from MY 10....................................................................................................................................................................................... 773 53 Cross Polo from MY 2010............................................................................................................................................................................... 775 54 Polo from MY 2014..................................................................................................................................................................................... 776 55 CrossPolo from MY 2014................................................................................................................................................................................ 778 56 Scirocco from MY 2009................................................................................................................................................................................. 779 57 Scirocco from MY 2015................................................................................................................................................................................. 780 58 Sharan from MY 1996................................................................................................................................................................................... 781 58.1 Retrofitting Trailer Hitch in Sharan BlueMotion................................................................................................................................................. 782 59 Sharan from MY 2011................................................................................................................................................................................... 783 60 Tiguan from MY 2008................................................................................................................................................................................... 784 60.1 Tiguan Trend & Fun/Sport & Style................................................................................................................................................................ 784 60.2 Tiguan Track & Field............................................................................................................................................................................ 785 61 Touran from MY 2003................................................................................................................................................................................... 788 62 CrossTouran........................................................................................................................................................................................... 790 63 Touareg from MY 2003.................................................................................................................................................................................. 791 64 Touareg from MY 10.................................................................................................................................................................................... 792 65 up! from MY 2012...................................................................................................................................................................................... 793 66 e-up! from MY 2014.................................................................................................................................................................................... 794 67 Vento from MY 1992.................................................................................................................................................................................... 795 68 Revision History...................................................................................................................................................................................... 796 01-Engine Mechanical & Systems.pdf (p.800-1223)...................................................................................................................................................................... 800 01-01 Engine Mechanical Fuel Injection and Ignition.............................................................................................................................................................. 800 00 – General, Technical Data................................................................................................................................................................................. 808 1 Identification......................................................................................................................................................................................... 808 1.1 Engine Number/Engine Specifications.............................................................................................................................................................. 808 2 Safety Precautions..................................................................................................................................................................................... 810 2.1 Safety Precautions when Working on Fuel Supply System............................................................................................................................................ 810 2.2 Safety Precautions, Working on Start/Stop System................................................................................................................................................. 810 2.3 Safety Precautions during Road Test with Testing Equipment....................................................................................................................................... 811 2.4 Ignition System Safety Precautions............................................................................................................................................................... 811 2.5 Safety Precautions, Working on Cooling System.................................................................................................................................................... 812 3 Repair Information..................................................................................................................................................................................... 813 3.1 Guidelines for Clean Working Conditions.......................................................................................................................................................... 813 3.2 Foreign Objects in Engine........................................................................................................................................................................ 813 3.3 Contact Corrosion................................................................................................................................................................................ 813 3.4 Wire Routing and Securing........................................................................................................................................................................ 814 3.5 Radiator and Condenser Assembly.................................................................................................................................................................. 814 3.6 Vacuum System, Checking.......................................................................................................................................................................... 814 4 Special Tools.......................................................................................................................................................................................... 815 10 – Engine Assembly......................................................................................................................................................................................... 816 1 Engine, Removing and Installing........................................................................................................................................................................ 816 1.1 Engine, Removing................................................................................................................................................................................. 816 1.2 Engine and Transmission, Separating.............................................................................................................................................................. 824 1.2.1 Engine and Transmission, Separating, Vehicles with Manual Transmission..................................................................................................................... 824 1.2.2 Engine and Transmission, Separating, Vehicles with DSG® Transmission....................................................................................................................... 826 1.3 Engine, Securing to Engine and Transmission Holder............................................................................................................................................... 828 1.4 Engine, Installing............................................................................................................................................................................... 829 2 Subframe Mount......................................................................................................................................................................................... 833 2.1 Overview - Subframe Mount........................................................................................................................................................................ 833 2.2 Engine, Supporting in Installation Position...................................................................................................................................................... 834 2.3 Engine Mount, Removing and Installing............................................................................................................................................................ 837 2.4 Transmission Mount, Removing and Installing...................................................................................................................................................... 837 2.5 Pendulum Support, Removing and Installing........................................................................................................................................................ 839 2.6 Subframe Mount, Checking Adjustment.............................................................................................................................................................. 839 2.7 Subframe Mount, Adjusting........................................................................................................................................................................ 839 3 Engine Cover........................................................................................................................................................................................... 841 3.1 Engine Cover, Removing and Installing............................................................................................................................................................ 841 4 Special Tools.......................................................................................................................................................................................... 842 13 – Crankshaft, Cylinder Block.............................................................................................................................................................................. 846 1 Cylinder Block, Belt Pulley Side....................................................................................................................................................................... 846 1.1 Overview - Cylinder Block, Belt Pulley Side...................................................................................................................................................... 846 1.2 Ribbed Belt, Removing and Installing............................................................................................................................................................. 848 1.3 Ribbed Belt Tensioner, Removing and Installing................................................................................................................................................... 849 1.4 Sub-Assembly Bracket, Removing and Installing.................................................................................................................................................... 849 1.5 Vibration Damper, Removing and Installing........................................................................................................................................................ 851 1.6 Engine Support, Removing and Installing.......................................................................................................................................................... 856 1.7 Crankshaft Seal, Replacing, Belt Pulley Side..................................................................................................................................................... 857 2 Cylinder Block, Transmission Side...................................................................................................................................................................... 859 2.1 Overview - Cylinder Block, Transmission Side..................................................................................................................................................... 859 2.2 Flywheel, Removing and Installing................................................................................................................................................................ 860 2.3 Sealing Flange, Removing and Installing, Transmission Side....................................................................................................................................... 861 3 Crankshaft............................................................................................................................................................................................. 864 3.1 Overview - Crankshaft............................................................................................................................................................................ 864 3.2 Sensor Wheel, Removing and Installing............................................................................................................................................................ 866 3.3 Crankshaft Needle Bearing, Replacing............................................................................................................................................................. 866 3.4 Main Bearing Shells Allocation................................................................................................................................................................... 867 3.5 Crankshaft Dimensions............................................................................................................................................................................ 868 3.6 Crankshaft, Measuring Axial Clearance............................................................................................................................................................ 869 3.7 Crankshaft, Measuring Radial Clearance........................................................................................................................................................... 869 4 Balance Shaft.......................................................................................................................................................................................... 871 4.1 Overview - Balance Shaft......................................................................................................................................................................... 871 4.2 Balance Shaft, Removing and Installing........................................................................................................................................................... 872 4.2.1 Balance Shaft Intake Side, Removing and Installing......................................................................................................................................... 872 4.2.2 Exhaust Side Balance Shaft, Removing and Installing........................................................................................................................................ 875 4.3 Balance Shaft Sealing Ring, Replacing, Intake Side............................................................................................................................................... 877 5 Piston and Connecting Rod.............................................................................................................................................................................. 879 5.1 Overview - Piston and Connecting Rod............................................................................................................................................................. 879 5.2 Pistons, Removing and Installing................................................................................................................................................................. 880 5.3 New Connecting Rod, Separating................................................................................................................................................................... 881 5.4 Pistons and Cylinder Bore, Checking.............................................................................................................................................................. 882 5.5 Connecting Rods, Checking Radial Clearance....................................................................................................................................................... 884 6 Special Tools.......................................................................................................................................................................................... 885 15 – Cylinder Head, Valvetrain............................................................................................................................................................................... 889 1 Timing Chain Cover..................................................................................................................................................................................... 889 1.1 Overview - Timing Chain Cover.................................................................................................................................................................... 889 1.2 Upper Timing Chain Cover, Removing and Installing................................................................................................................................................ 891 1.3 Lower Timing Chain Cover, Removing and Installing................................................................................................................................................ 893 2 Chain Drive............................................................................................................................................................................................ 898 2.1 Overview - Camshaft Timing Chains................................................................................................................................................................ 898 2.2 Overview - Balance Shaft Drive Chain............................................................................................................................................................. 899 2.3 Camshaft Timing Chain, Removing and Installing................................................................................................................................................... 901 2.4 Balance Shaft Drive Chain, Removing and Installing............................................................................................................................................... 913 2.5 Chain Length, Checking........................................................................................................................................................................... 915 2.6 Valve Timing, Checking........................................................................................................................................................................... 916 3 Cylinder Head.......................................................................................................................................................................................... 919 3.1 Overview - Cylinder Head......................................................................................................................................................................... 919 3.2 Cylinder Head, Removing and Installing........................................................................................................................................................... 921 3.3 Vacuum Pump, Removing and Installing............................................................................................................................................................. 928 3.4 Compression, Checking............................................................................................................................................................................ 929 4 Valvetrain............................................................................................................................................................................................. 931 4.1 Overview - Valvetrain............................................................................................................................................................................ 931 4.2 Camshaft, Removing and Installing................................................................................................................................................................ 935 4.2.1 Camshaft Timing Chain Glide Rails, Differentiating Characteristics......................................................................................................................... 935 4.2.2 Camshaft, Removing and Installing, Version A............................................................................................................................................... 935 4.2.3 Camshaft, Removing and Installing, Version B............................................................................................................................................... 948 4.3 Sliding Bar Ball, Installing..................................................................................................................................................................... 959 4.4 Valve Stem Seals, Removing and Installing........................................................................................................................................................ 960 4.4.1 Valve Stem Seals, Removing and Installing, Cylinder Head Installed......................................................................................................................... 960 4.4.2 Valve Stem Seals, Removing and Installing, Cylinder Head Removed........................................................................................................................... 964 4.5 Camshaft Adjustment Valve 1 -N205- / Exhaust Camshaft Adjustment Valve 1 -N318-, Removing and Installing......................................................................................... 967 4.6 Cam Adjustment Actuator 1 -F366- / Cam Adjustment Actuator 8 -F373-, Removing and Installing..................................................................................................... 968 5 Intake and Exhaust Valves.............................................................................................................................................................................. 969 5.1 Valve Guides, Checking........................................................................................................................................................................... 969 5.2 Valves, Checking................................................................................................................................................................................. 969 5.3 Valve Dimensions................................................................................................................................................................................. 969 6 Special Tools.......................................................................................................................................................................................... 970 17 – Lubrication............................................................................................................................................................................................. 978 1 Oil Pan/Oil Pump....................................................................................................................................................................................... 978 1.1 Overview - Oil Pan/Oil Pump...................................................................................................................................................................... 978 1.2 Oil Level Thermal Sensor -G266-, Removing and Installing......................................................................................................................................... 981 1.3 Oil Pan Lower Section, Removing and Installing................................................................................................................................................... 981 1.4 Oil Pump, Removing and Installing................................................................................................................................................................ 981 1.5 Oil Pan Upper Section, Removing and Installing................................................................................................................................................... 983 1.6 Engine Oil....................................................................................................................................................................................... 987 2 Engine Oil Cooler...................................................................................................................................................................................... 989 2.1 Overview - Engine Oil Cooler..................................................................................................................................................................... 989 2.2 Engine Oil Cooler, Removing and Installing....................................................................................................................................................... 989 2.3 Mechanical Switch Valve, Removing and Installing................................................................................................................................................. 990 3 Crankcase Ventilation.................................................................................................................................................................................. 991 3.1 Overview - Crankcase Ventilation................................................................................................................................................................. 991 3.2 Oil Separator, Removing and Installing........................................................................................................................................................... 992 4 Oil Filter/Oil Pressure Switch......................................................................................................................................................................... 993 4.1 Overview - Oil Filter............................................................................................................................................................................ 993 4.2 Overview - Oil Pressure Switch/Oil Pressure Regulation Valve..................................................................................................................................... 994 4.3 Piston Cooling Nozzle Control Valve -N522-, Removing and Installing.............................................................................................................................. 995 4.4 Oil Pressure Regulation Valve -N428-, Removing and Installing.................................................................................................................................... 995 4.5 Oil Pressure Switch -F1-, Removing and Installing................................................................................................................................................ 996 4.6 Reduced Oil Pressure Switch -F378-, Removing and Installing...................................................................................................................................... 997 4.7 Oil Pressure Switch, Level 3 -F447-, Removing and Installing..................................................................................................................................... 997 4.8 Oil Pressure, Checking........................................................................................................................................................................... 999 4.8.1 Engine Oil Pressure, Checking.............................................................................................................................................................. 999 4.8.2 Piston Spray Nozzles Oil Pressure, Checking................................................................................................................................................1000 5 Special Tools..........................................................................................................................................................................................1002 19 – Cooling System..........................................................................................................................................................................................1004 1 Coolant System/Coolant.................................................................................................................................................................................1004 1.1 Connection Diagram - Coolant Hoses...............................................................................................................................................................1004 1.1.1 Vehicles with DSG® Transmission............................................................................................................................................................1004 1.1.2 Vehicles with Manual Transmission..........................................................................................................................................................1006 1.2 Coolant, Draining and Filling....................................................................................................................................................................1008 1.3 Coolant System, Checking for Leaks...............................................................................................................................................................1013 2 Coolant Pump/Thermostat................................................................................................................................................................................1015 2.1 Overview - Coolant Pump/Thermostat...............................................................................................................................................................1015 2.2 Overview - Electric Coolant Pump.................................................................................................................................................................1018 2.3 Overview - Engine Coolant Temperature Sensor.....................................................................................................................................................1020 2.4 Coolant Pump Toothed Belt, Removing and Installing...............................................................................................................................................1020 2.5 Coolant Pump, Removing and Installing............................................................................................................................................................1022 2.6 After-Run Coolant Pump -V51-, Removing and Installing............................................................................................................................................1024 2.7 Coolant Shut-Off Valve -N82-, Removing and Installing............................................................................................................................................1025 2.8 Transmission Coolant Valve -N488-, Removing and Installing.......................................................................................................................................1026 2.9 Engine Temperature Control Actuator -N493-, Removing and Installing..............................................................................................................................1027 2.10 Engine Coolant Temperature Sensor -G62-, Removing and Installing................................................................................................................................1029 2.11 Engine Coolant Temperature Sensor on Radiator Outlet -G83-, Removing and Installing.............................................................................................................1030 3 Coolant Pipes..........................................................................................................................................................................................1032 3.1 Overview - Coolant Pipes.........................................................................................................................................................................1032 3.2 Coolant Pipe on Front Engine, Removing and Installing............................................................................................................................................1032 3.3 Coolant Pipe on Upper Engine, Removing and Installing............................................................................................................................................1034 3.4 Coolant Pipe on Fan Shroud, Removing and Installing..............................................................................................................................................1035 4 Radiator/Radiator Fan..................................................................................................................................................................................1037 4.1 Overview - Radiator/Radiator Fan.................................................................................................................................................................1037 4.2 Overview - Fan Shroud and Radiator Fan...........................................................................................................................................................1039 4.3 Overview - Auxiliary Cooler......................................................................................................................................................................1039 4.4 Radiator, Removing and Installing................................................................................................................................................................1040 4.5 Auxiliary Cooler, Removing and Installing........................................................................................................................................................1042 4.6 Fan Shroud, Removing and Installing..............................................................................................................................................................1044 4.7 Radiator Fan, Removing and Installing............................................................................................................................................................1045 4.7.1 Radiator Fan -V7-, Removing and Installing.................................................................................................................................................1045 4.7.2 Radiator Fan 2 -V177-, Removing and Installing.............................................................................................................................................1046 5 Special Tools..........................................................................................................................................................................................1047 21 – Turbocharger, Supercharger..............................................................................................................................................................................1050 1 Turbocharger...........................................................................................................................................................................................1050 1.1 Overview - Turbocharger..........................................................................................................................................................................1050 1.2 Turbocharger, Removing and Installing............................................................................................................................................................1052 2 Charge Air System......................................................................................................................................................................................1057 2.1 Overview - Charge Air System.....................................................................................................................................................................1057 2.2 Overview - Charge Air Hose Connections...........................................................................................................................................................1058 2.3 Charge Air Cooler, Removing and Installing.......................................................................................................................................................1058 2.4 Charge Air Pressure Sensor -G31-, Removing and Installing........................................................................................................................................1059 2.5 Charge Air System, Checking for Leaks............................................................................................................................................................1059 3 Special Tools..........................................................................................................................................................................................1062 24 – Multiport Fuel Injection................................................................................................................................................................................1063 1 Injection System.......................................................................................................................................................................................1063 1.1 Component Location Overview - Injection System...................................................................................................................................................1063 1.2 High Fuel Pressure, Reducing.....................................................................................................................................................................1073 2 Air Filter.............................................................................................................................................................................................1075 2.1 Overview - Air Filter Housing....................................................................................................................................................................1075 2.2 Air Filter Housing, Removing and Installing......................................................................................................................................................1076 3 Intake Manifold........................................................................................................................................................................................1077 3.1 Overview - Intake Manifold.......................................................................................................................................................................1077 3.2 Intake Manifold, Removing and Installing.........................................................................................................................................................1078 3.3 Throttle Valve Control Module -GX3-, Removing and Installing.....................................................................................................................................1083 3.4 Throttle Valve Control Module , Cleaning.........................................................................................................................................................1085 4 Fuel Injectors.........................................................................................................................................................................................1087 4.1 Overview - Fuel Rail with Fuel Injectors.........................................................................................................................................................1087 4.1.1 Overview - Fuel Rail with Fuel Injectors, Direct Fuel Injection............................................................................................................................1087 4.1.2 Overview - Fuel Rail with Fuel Injectors, Multi-Port Fuel Injection........................................................................................................................1088 4.2 Fuel Rail, Removing and Installing...............................................................................................................................................................1089 4.3 Fuel Injectors, Removing and Installing..........................................................................................................................................................1090 4.3.1 Fuel Injectors, Removing and Installing, Direct Fuel Injection.............................................................................................................................1090 4.3.2 Fuel Injectors, Removing and Installing, Multi-Point Fuel Injection........................................................................................................................1092 4.4 Fuel Injector Seals, Replacing...................................................................................................................................................................1093 4.5 Fuel Injectors, Cleaning.........................................................................................................................................................................1095 5 Sensors................................................................................................................................................................................................1097 5.1 Overview - Structure Borne Sound Actuator and Control Module.....................................................................................................................................1097 5.2 Fuel Pressure Sensor -G247-, Removing and Installing.............................................................................................................................................1098 5.3 Low Fuel Pressure Sensor -G410-, Removing and Installing.........................................................................................................................................1100 5.4 Intake Air Temperature Sensor -G42- / Manifold Absolute Pressure Sensor -G71-, Removing and Installing...........................................................................................1101 5.5 Structure-Borne Sound Actuator -R214-, Removing and Installing...................................................................................................................................1102 6 High Pressure Pump.....................................................................................................................................................................................1103 6.1 Overview - High Pressure Pump....................................................................................................................................................................1103 6.2 High Pressure Pump, Removing and Installing......................................................................................................................................................1104 7 Heated Oxygen Sensor...................................................................................................................................................................................1108 7.1 Overview - Heated Oxygen Sensor..................................................................................................................................................................1108 7.2 Heated Oxygen Sensor, Removing and Installing....................................................................................................................................................1109 7.2.1 Oxygen Sensor 1 before Catalytic Converter -GX10-, Removing and Installing.................................................................................................................1109 7.2.2 Oxygen Sensor 1 after Catalytic Converter -GX7-, Removing and Installing...................................................................................................................1110 8 Engine Control Module..................................................................................................................................................................................1111 8.1 Engine Control Module -J623-, Removing and Installing............................................................................................................................................1111 8.1.1 Engine Control Module -J623-, Removing and Installing, without Protective Housing..........................................................................................................1111 8.1.2 Engine Control Module -J623- with Protective Housing, Removing and Installing..............................................................................................................1112 9 Special Tools..........................................................................................................................................................................................1115 26 – Exhaust System, Emission Controls.......................................................................................................................................................................1117 1 Exhaust Pipes/Mufflers.................................................................................................................................................................................1117 1.1 Overview - Muffler...............................................................................................................................................................................1117 1.1.1 Overview - Muffler.........................................................................................................................................................................1117 1.1.2 Overview - Muffler, Wagon, 4MOTION.........................................................................................................................................................1119 1.2 Muffler, Removing and Installing.................................................................................................................................................................1120 1.3 Exhaust Pipes/Mufflers, Disconnecting............................................................................................................................................................1120 1.4 Exhaust System, Installing without Tension.......................................................................................................................................................1121 1.5 Tail Pipes, Aligning.............................................................................................................................................................................1122 1.6 Exhaust System, Checking for Leaks...............................................................................................................................................................1122 1.7 Clamping Sleeve Installation Position............................................................................................................................................................1123 2 Emissions Control......................................................................................................................................................................................1124 2.1 Overview - Emissions Control.....................................................................................................................................................................1124 2.2 Catalytic Converter, Removing and Installing.....................................................................................................................................................1126 2.3 Exhaust Door Control Units -J883- / -J945-, Removing and Installing..............................................................................................................................1127 3 Secondary Air System...................................................................................................................................................................................1129 3.1 Overview - Secondary Air Injection System........................................................................................................................................................1129 3.2 Secondary Air Injection Pump Motor -V101-, Removing and Installing...............................................................................................................................1130 3.3 Secondary Air Injection Sensor 1 -G609-, Removing and Installing.................................................................................................................................1130 3.4 Secondary Air Injection Solenoid Valve -N112-, Removing and Installing...........................................................................................................................1131 4 Special Tools..........................................................................................................................................................................................1133 28 – Ignition/Glow Plug System...............................................................................................................................................................................1134 1 Ignition System........................................................................................................................................................................................1134 1.1 Overview - Ignition System.......................................................................................................................................................................1134 1.2 Ignition Coils with Power Output Stages, Removing and Installing.................................................................................................................................1135 1.3 Knock Sensor 1 -G61-, Removing and Installing....................................................................................................................................................1137 1.4 Camshaft Position Sensor, Removing and Installing................................................................................................................................................1137 1.4.1 Camshaft Position Sensor -G40-, Removing and Installing....................................................................................................................................1137 1.4.2 Camshaft Position Sensor 3 -G300-, Removing and Installing.................................................................................................................................1138 1.5 Engine Speed Sensor -G28-, Removing and Installing...............................................................................................................................................1138 2 Special Tools..........................................................................................................................................................................................1140 3 Revision History.......................................................................................................................................................................................1141 01-02 Fuel Supply-Gasoline Engines...............................................................................................................................................................................1145 00 – General, Technical Data.................................................................................................................................................................................1149 1 Safety Precautions.....................................................................................................................................................................................1149 1.1 Safety Precautions when Working on Fuel Supply System............................................................................................................................................1149 1.2 Safety Precautions during Road Test with Testing Equipment.......................................................................................................................................1149 1.3 Safety Precautions when Working on Start/Stop System.............................................................................................................................................1150 2 Identification.........................................................................................................................................................................................1151 2.1 Engine Number/Engine Specifications..............................................................................................................................................................1151 3 General Information....................................................................................................................................................................................1152 3.1 Parking/Auxiliary Heater and Fuel System Guidelines for Clean Working Conditions.................................................................................................................1152 4 Repair Information.....................................................................................................................................................................................1153 4.1 Line Routing and Securing........................................................................................................................................................................1153 4.2 General Repair Information.......................................................................................................................................................................1153 20 – Fuel Supply.............................................................................................................................................................................................1154 1 Fuel Tank..............................................................................................................................................................................................1154 1.1 Overview - Fuel Tank.............................................................................................................................................................................1154 1.1.1 Overview - Fuel Tank.......................................................................................................................................................................1154 1.1.2 Overview - Fuel Tank.......................................................................................................................................................................1156 1.2 Fuel Tank, Removing and Installing...............................................................................................................................................................1158 1.2.1 Fuel Tank, Removing and Installing.........................................................................................................................................................1158 1.2.2 Fuel Tank, Removing and Installing.........................................................................................................................................................1163 1.3 Fuel Tank, Draining..............................................................................................................................................................................1167 1.3.1 Fuel Tank, Draining When More than 3/4 Full................................................................................................................................................1167 1.3.2 Fuel Tank, Draining When Less Than 3/4 Full................................................................................................................................................1169 2 Fuel Delivery Unit/Fuel Level Sensor...................................................................................................................................................................1173 2.1 Overview - Fuel Delivery Unit/Fuel Level Sensor..................................................................................................................................................1173 2.2 Fuel Delivery Unit/Fuel Level Sensor, Removing and Installing....................................................................................................................................1175 2.3 Fuel Level Sensor -G-, Removing and Installing...................................................................................................................................................1178 2.4 Fuel Level Sensor 2 -G169-, Removing and Installing..............................................................................................................................................1179 3 Connector Couplings....................................................................................................................................................................................1182 3.1 Connector Couplings, Disconnecting...............................................................................................................................................................1182 4 Fuel Filter............................................................................................................................................................................................1186 5 EVAP System............................................................................................................................................................................................1187 5.1 Connection Diagram - EVAP System.................................................................................................................................................................1187 5.1.1 Connection Diagram - EVAP System...........................................................................................................................................................1187 5.2 Overview - EVAP System...........................................................................................................................................................................1188 5.2.1 Overview - EVAP System.....................................................................................................................................................................1188 5.2.2 Overview - EVAP System.....................................................................................................................................................................1189 5.3 EVAP Canister, Removing and Installing...........................................................................................................................................................1190 5.3.1 EVAP Canister, Removing and Installing.....................................................................................................................................................1190 5.3.2 EVAP Canister, Removing and Installing.....................................................................................................................................................1191 5.3.3 EVAP System Air filter, Removing and Installing............................................................................................................................................1192 5.3.4 Fuel Tank Pressure Sensor -G400-, Removing and Installing..................................................................................................................................1192 5.3.5 Fuel Tank Leak Detection Control Module -J909-, Removing and Installing....................................................................................................................1193 5.3.6 Fuel System, Checking for Leaks............................................................................................................................................................1194 5.4 Fuel Tank, Checking Ventilation..................................................................................................................................................................1194 6 Accelerator Mechanism..................................................................................................................................................................................1199 6.1 Overview - Accelerator Pedal Module..............................................................................................................................................................1199 6.2 Accelerator Pedal Module -GX2-, Removing and Installing..........................................................................................................................................1200 7 Fuel Pump..............................................................................................................................................................................................1201 7.1 Transfer Fuel Pump -G6-, Checking................................................................................................................................................................1201 7.1.1 Fuel Pressure, Checking....................................................................................................................................................................1201 7.1.2 Residual Pressure, Checking................................................................................................................................................................1204 7.1.3 Fuel Delivery Rate, Checking...............................................................................................................................................................1208 7.2 Fuel Pump Control Module -J538-, Removing and Installing.........................................................................................................................................1212 7.3 Suction Jet Pump, Removing and Installing........................................................................................................................................................1213 8 Special Tools..........................................................................................................................................................................................1215 9 Revision History.......................................................................................................................................................................................1220 02-Engine Performance.pdf (p.1224-1708)..............................................................................................................................................................................1224 02-00 Generic Scan Tool..........................................................................................................................................................................................1224 ST – Generic Scan Tool.......................................................................................................................................................................................1228 1 General Information....................................................................................................................................................................................1228 1.1 Safety Precautions...............................................................................................................................................................................1229 1.2 Clean Working Conditions.........................................................................................................................................................................1230 1.3 High Voltage System General Warnings.............................................................................................................................................................1231 2 Description and Operation..............................................................................................................................................................................1237 2.1 On Board Diagnostic Systems......................................................................................................................................................................1237 2.2 Evaporative Emission System......................................................................................................................................................................1237 2.2.1 Leak Detection Pump (LDP) Evap System......................................................................................................................................................1238 2.2.2 Tank Leak Diagnostic Module (DM - TL) Evap System..........................................................................................................................................1238 2.2.3 Natural Vacuum Leak Detection (NVLD) Evap System...........................................................................................................................................1238 2.2.4 EVAP System, Checking for Leaks............................................................................................................................................................1238 2.3 Electronic Throttle Control (ETC) System.........................................................................................................................................................1239 2.4 Electronic Power Control (EPC) Warning Lamp......................................................................................................................................................1239 2.5 Engine Control Module (ECM)......................................................................................................................................................................1240 2.6 Malfunction Indicator Lamp (MIL).................................................................................................................................................................1240 2.7 Controller Area Network (CAN)....................................................................................................................................................................1240 2.8 Fuel Supply......................................................................................................................................................................................1241 2.9 Ignition and Timing..............................................................................................................................................................................1242 2.10 Variable Valve Timing...........................................................................................................................................................................1243 2.11 Exhaust-Gas Recirculation (EGR) System..........................................................................................................................................................1243 2.12 Secondary Air Injection.........................................................................................................................................................................1243 2.13 Exhaust Systems.................................................................................................................................................................................1243 3 Diagnosis and Testing .................................................................................................................................................................................1245 3.1 Preliminary Check................................................................................................................................................................................1245 3.2 Readiness Code...................................................................................................................................................................................1246 3.3 Diagnostic Modes 01 - 09.........................................................................................................................................................................1248 3.3.1 Diagnostic Mode 01 - Read Current System Data..............................................................................................................................................1248 3.3.2 Diagnostic Mode 02 - Read Operating Conditions.............................................................................................................................................1250 3.3.3 Diagnostic Mode 03 - Read DTC Memory.......................................................................................................................................................1251 3.3.4 Diagnostic Mode 04 - Erase DTC Memory......................................................................................................................................................1253 3.3.5 Diagnostic Mode 05 - Read Oxygen Sensor Monitoring Test Results............................................................................................................................1253 3.3.6 Diagnostic Mode 06 - Read Test Results for Specific Diagnostic Functions, 2015 MY..........................................................................................................1254 3.3.7 Diagnostic Mode 06 - Read Test Results for Specific Diagnostic Functions, 2016 MY..........................................................................................................1261 3.3.8 Diagnostic Mode 07 - Read Faults Detected During the Current or Last Driving Cycle.........................................................................................................1268 3.3.9 Diagnostic Mode 08 - Request Control of On-Board System, Test or Component.................................................................................................................1269 3.3.10 Diagnostic Mode 09 - Request Vehicle Information..........................................................................................................................................1269 3.3.11 Diagnostic Mode 0A - Check Permanent DTC Memory...........................................................................................................................................1270 3.4 Engine DTC Tables................................................................................................................................................................................1272 3.4.1 Engine Control Module, 2015 MY.............................................................................................................................................................1272 3.4.2 Engine Control Module, 2016 MY.............................................................................................................................................................1325 3.5 Transmission DTC Tables..........................................................................................................................................................................1523 3.5.1 Transmission Mechatronic, DSG 6-spd 02E (2015 MY)..........................................................................................................................................1524 3.5.2 Transmission Mechatronic, DSG 6-spd 02E (2016 MY)..........................................................................................................................................1554 3.6 Diagnostic Procedures............................................................................................................................................................................1583 3.6.1 Accelerator Pedal Module -GX2-, Checking...................................................................................................................................................1584 3.6.2 Cam Adjustment Actuators , Checking........................................................................................................................................................1586 3.6.3 Camshaft Adjustment Valve 1 -N205-, Checking...............................................................................................................................................1589 3.6.4 Camshaft Position Sensor 3 - G300-, Checking...............................................................................................................................................1591 3.6.5 Camshaft Position Sensor -G40-, Checking...................................................................................................................................................1595 3.6.6 Charge Air Pressure Sensor -G31-, Checking.................................................................................................................................................1599 3.6.7 Charge Pressure Actuator -V465- / Charge Pressure Actuator Position Sensor -G581-, Checking................................................................................................1601 3.6.8 Engine Component Power Supply Relay -J757-, Checking.......................................................................................................................................1605 3.6.9 Engine Coolant Temperature Sensor -G62-, Checking..........................................................................................................................................1607 3.6.10 Engine Coolant Temperature Sensor On Radiator Outlet -G83-, Checking......................................................................................................................1609 3.6.11 Engine Speed Sensor -G28-, Checking.......................................................................................................................................................1611 3.6.12 Engine Temperature Control Actuator -N493-, Checking......................................................................................................................................1615 3.6.13 EVAP Canister Purge Regulator Valve 1 -N80-, Checking.....................................................................................................................................1619 3.6.14 Exhaust Camshaft Adjustment Valve 1 -N318-, Checking......................................................................................................................................1621 3.6.15 Fuel Injectors , Checking.................................................................................................................................................................1623 3.6.16 Fuel Pressure Regulator Valve -N276-, Checking............................................................................................................................................1625 3.6.17 Fuel Pressure Sensor -G247-, Checking.....................................................................................................................................................1627 3.6.18 Fuel Pump Control Module -J538- /Fuel Delivery Unit -GX1-, Checking.......................................................................................................................1631 3.6.19 Fuel Tank Leak Detection Control Module -J909- / Fuel Tank Pressure Sensor -G400-, Checking...............................................................................................1633 3.6.20 Ignition Coils with Power Output Stage, Checking..........................................................................................................................................1636 3.6.21 Intake Manifold Runner Control Valve -N316-, Checking.....................................................................................................................................1638 3.6.22 Intake Manifold Runner Position Sensor -G336-, Checking...................................................................................................................................1640 3.6.23 Intake Manifold Sensor -GX9-, Checking....................................................................................................................................................1644 3.6.24 Knock Sensor 1 - G61-, Checking...........................................................................................................................................................1648 3.6.25 Motronic Engine Control Module Power Supply Relay -J271-, Checking........................................................................................................................1650 3.6.26 Outside Air Temperature Sensor -G17-, Checking............................................................................................................................................1652 3.6.27 Oxygen Sensor 1 After Catalytic Converter -GX7-, Checking.................................................................................................................................1654 3.6.28 Oxygen Sensor 1 Before Catalytic Converter -GX10-, Checking...............................................................................................................................1657 3.6.29 Secondary Air Injection Pump Motor -V101- / Secondary Air Injection Pump Relay -J299-, Checking...........................................................................................1660 3.6.30 Secondary Air Injection Sensor 1 -G609- / Secondary Air Injection Solenoid Valve -N112-, Checking.........................................................................................1663 3.6.31 Throttle Valve Control Module -GX3-, Checking.............................................................................................................................................1666 3.6.32 Turbocharger Recirculation Valve -N249-, Checking.........................................................................................................................................1669 3.6.33 Vehicle Speed Signal, Checking............................................................................................................................................................1671 02-01 VW New OBD II drive cycle procedure........................................................................................................................................................................1676 02-02 Volkswagen Engine & transmission Fault Codes...............................................................................................................................................................1679 02-03 VW Revised Immobilizer Service Program for independent Workshops...........................................................................................................................................1703 02-04 VW Q1 2015 CAL IDs and CVNs................................................................................................................................................................................1704 03-Manual Transmission & Rear Final Drive.pdf (p.1709-1904)..........................................................................................................................................................1709 03-02A Rear Final Drive..........................................................................................................................................................................................1709 00 – General, Technical Data.................................................................................................................................................................................1713 1 Safety Precautions.....................................................................................................................................................................................1713 1.1 Road Test with Testing Equipment Safety Precautions..............................................................................................................................................1713 1.2 Start/Stop System Safety Precautions.............................................................................................................................................................1714 2 Identification.........................................................................................................................................................................................1715 2.1 Final Drive Identification.......................................................................................................................................................................1715 2.1.1 Final Drive Code 02D/0BS/0AY...............................................................................................................................................................1715 2.1.2 Final Drive Identification 0CQ/0CR.........................................................................................................................................................1715 3 Repair Information.....................................................................................................................................................................................1716 3.1 General Repair Information.......................................................................................................................................................................1716 3.1.1 Oil........................................................................................................................................................................................1716 3.1.2 Fasteners..................................................................................................................................................................................1716 3.1.3 Bearings...................................................................................................................................................................................1716 3.1.4 Adjusting Shims............................................................................................................................................................................1717 3.2 Seals, Sealing Rings.............................................................................................................................................................................1717 3.3 Bolts and Nuts...................................................................................................................................................................................1717 4 Technical Data.........................................................................................................................................................................................1718 4.1 Transmission/Engine Allocation...................................................................................................................................................................1718 4.1.1 Transmission-Engine Allocation, CC from MY 2012, Passat from MY 2011, Passat Wagon from MY 2011............................................................................................1718 4.1.2 Transmission-Engine Allocation, Golf from MY 2013, Golf Wagon from MY 2014.................................................................................................................1718 4.1.3 Transmission-Engine Allocation, Passat from MY 2015, Passat Wagon from MY 2015.............................................................................................................1718 4.1.4 Transmission/Engine Allocation, Sharan from MY 2016........................................................................................................................................1719 4.2 Capacities.......................................................................................................................................................................................1719 4.2.1 Final Drive 0BS Capacity...................................................................................................................................................................1719 4.2.2 Final Drive 0AY, Capacity..................................................................................................................................................................1720 4.2.3 Capacities, Final Drive 0CQ................................................................................................................................................................1720 4.2.4 Capacities, Final Drive 0CR................................................................................................................................................................1720 5 Electrical Components..................................................................................................................................................................................1722 5.1 Component Location Overview - Electrical Components..............................................................................................................................................1722 5.1.1 Electrical Component Locations Overview, Rear Final Drive “0BS” with Haldex Clutch Generation IV...........................................................................................1722 5.1.2 Electrical Component Locations Overview, Rear Final Drive “0CQ/0CR/0AY” with Haldex Clutch Generation V....................................................................................1723 39 – Final Drive, Differential...............................................................................................................................................................................1724 1 Final Drive............................................................................................................................................................................................1724 1.1 Overview - Final Drive...........................................................................................................................................................................1724 1.2 Final Drive, Removing and Installing.............................................................................................................................................................1725 1.2.1 Final Drive, Removing and Installing, CC from 2012, Passat from 2011, Passat Wagon from 2011...............................................................................................1725 1.2.2 Final Drive, Removing and Installing, Golf from MY 2013....................................................................................................................................1732 1.2.3 Final Drive, Removing and Installing, Golf Wagon from MY 2014..............................................................................................................................1739 1.2.4 Final Drive, Removing and Installing, Passat from 2015, Passat Wagon from 2015.............................................................................................................1747 1.2.5 Rear Final Drive, Removing and Installing, Sharan from MY 2016.............................................................................................................................1754 2 Subframe Mount.........................................................................................................................................................................................1758 2.1 Overview - Subframe Mount........................................................................................................................................................................1758 2.1.1 Overview - Subframe Mount. Final Drive 0BS, 0CR, 0AY.......................................................................................................................................1758 2.1.2 Overview - Subframe Mount. Final Drive 0CQ.................................................................................................................................................1759 2.2 Bonded Rubber Bushing, Removing and Installing...................................................................................................................................................1761 2.2.1 Bonded Rubber Bushing, Removing and Installing, Final Drive 0BS, 0CR, 0AY..................................................................................................................1761 2.2.2 Bonded Rubber Bushing, Removing and Installing, Final Drive 0CQ............................................................................................................................1763 3 Gear Oil...............................................................................................................................................................................................1766 3.1 Gear Oil, Checking Level.........................................................................................................................................................................1766 4 High-Performance Haldex Clutch Oil.....................................................................................................................................................................1767 4.1 Haldex Clutch Oil, Checking Level................................................................................................................................................................1767 4.2 High-Performance Haldex Clutch Oil, Draining and Filling.........................................................................................................................................1768 5 Seals..................................................................................................................................................................................................1770 5.1 Component Location Overview - Seals..............................................................................................................................................................1770 5.2 Right Seal, Replacing............................................................................................................................................................................1771 5.2.1 Right Seal, Replacing, Rear Final Drive 0BS................................................................................................................................................1771 5.2.2 Right Seal, Replacing, Rear Final Drive 0CQ/0CR/0AY........................................................................................................................................1772 5.3 Left Seal, Replacing.............................................................................................................................................................................1774 5.3.1 Left Seal, Replacing, Rear Final Drive 0BS.................................................................................................................................................1774 5.3.2 Left Seal, Replacing, Rear Final Drive 0CQ/0CR/0AY.........................................................................................................................................1776 5.4 Flange Shaft and Driveshaft Seal on Rear Final Drive, Replacing..................................................................................................................................1777 6 Haldex Clutch..........................................................................................................................................................................................1782 6.1 Function, Checking...............................................................................................................................................................................1782 6.2 Overview - Haldex Clutch.........................................................................................................................................................................1782 6.2.1 Overview - Haldex Clutch, Generation IV....................................................................................................................................................1782 6.2.2 Overview - Haldex Clutch, Generation V.....................................................................................................................................................1785 6.3 Haldex Clutch Pump -V181- Removing and Installing................................................................................................................................................1786 6.3.1 Haldex Clutch Pump -V181-, Removing and Installing, Generation IV..........................................................................................................................1786 6.3.2 Haldex Clutch Pump -V181-, Removing and Installing, Generation V...........................................................................................................................1788 6.4 Haldex Clutch, Removing and Installing...........................................................................................................................................................1790 6.4.1 Haldex Clutch, Removing and Installing, Generation IV......................................................................................................................................1790 6.4.2 Haldex Clutch, Removing and Installing, Generation V.......................................................................................................................................1795 6.5 All Wheel Drive Control Module -J492-, Removing and Installing...................................................................................................................................1798 6.5.1 All Wheel Drive Control Module -J492-, Removing and Installing, Generation IV..............................................................................................................1798 6.5.2 AWD Control Module -J492-, Removing and Installing, Generation V...........................................................................................................................1801 7 Driveshaft.............................................................................................................................................................................................1803 7.1 Overview - Driveshaft............................................................................................................................................................................1803 7.1.1 Overview - Driveshaft, CC from MY 2012, Passat from MY 2011, Passat Wagon from MY 2011, Golf from MY 2013, Golf Wagon from MY 2014, Passat from MY 2015 and Passat Wagon from MY 2015......1803 7.1.2 Overview - Propshaft, Sharan from MY 2016..................................................................................................................................................1805 7.2 Driveshaft, Removing and Installing..............................................................................................................................................................1806 7.2.1 Driveshaft, Removing and Installing, CC from 2012, Passat from 2011, Passat Wagon from 2011................................................................................................1806 7.2.2 Driveshaft, Removing and Installing, Golf from 2013, Golf Wagon from 2014..................................................................................................................1809 7.2.3 Driveshaft, Removing and Installing, Passat from MY 2015, Passat Wagon from MY 2015........................................................................................................1813 7.2.4 Propshaft, Removing and Installing, Sharan from MY 2016....................................................................................................................................1817 7.3 Front Flexible Disc, Removing and Installing.....................................................................................................................................................1820 7.4 Rear Flexible Disc, Removing and Installing......................................................................................................................................................1821 8 Special Tools..........................................................................................................................................................................................1826 9 Revision History.......................................................................................................................................................................................1835 03-02B Rear Final Drive (CJXC,CJXB,CYF)..........................................................................................................................................................................1839 00 – General, Technical Data.................................................................................................................................................................................1843 1 Safety Precautions.....................................................................................................................................................................................1843 1.1 Road Test with Testing Equipment Safety Precautions..............................................................................................................................................1843 1.2 Safety Precautions when Working on Start/Stop System.............................................................................................................................................1843 2 Identification.........................................................................................................................................................................................1844 2.1 Final Drive Identification.......................................................................................................................................................................1844 3 Repair Information.....................................................................................................................................................................................1845 3.1 General Repair Information.......................................................................................................................................................................1845 3.1.1 General Information........................................................................................................................................................................1845 3.1.2 Oil........................................................................................................................................................................................1845 3.1.3 Fasteners..................................................................................................................................................................................1845 3.1.4 Bearings...................................................................................................................................................................................1846 3.1.5 Shims......................................................................................................................................................................................1846 3.2 Seals and Gaskets................................................................................................................................................................................1846 3.3 Nuts and Bolts...................................................................................................................................................................................1846 4 Technical Data.........................................................................................................................................................................................1847 4.1 Transmission/Engine Allocation...................................................................................................................................................................1847 4.2 Capacities.......................................................................................................................................................................................1847 5 Electrical Components..................................................................................................................................................................................1848 5.1 Overview - Electrical Components.................................................................................................................................................................1848 39 – Final Drive, Differential...............................................................................................................................................................................1849 1 Final Drive............................................................................................................................................................................................1849 1.1 Overview - Final Drive...........................................................................................................................................................................1849 1.2 Final Drive, Removing and Installing.............................................................................................................................................................1849 2 Subframe Mount.........................................................................................................................................................................................1857 2.1 Overview - Subframe Mount........................................................................................................................................................................1857 2.2 Bonded Rubber Bushing, Removing and Installing...................................................................................................................................................1858 3 Gear Oil...............................................................................................................................................................................................1861 3.1 Overview - Drain and Check Plugs.................................................................................................................................................................1861 3.2 Gear Oil, Checking Level.........................................................................................................................................................................1861 4 High-Performance Haldex Clutch Oil.....................................................................................................................................................................1863 4.1 Haldex Clutch Oil, Checking Level................................................................................................................................................................1863 4.2 High-Performance Haldex Clutch Oil, Draining and Filling.........................................................................................................................................1863 4.3 High-Performance Haldex Clutch Oil, Changing.....................................................................................................................................................1865 5 Seals..................................................................................................................................................................................................1867 5.1 Overview - Seals.................................................................................................................................................................................1867 5.2 Right Seal, Replacing............................................................................................................................................................................1867 5.3 Left Seal, Replacing.............................................................................................................................................................................1869 5.4 Input Shaft Seal, Replacing......................................................................................................................................................................1870 6 Haldex Clutch..........................................................................................................................................................................................1876 6.1 Overview - Haldex Clutch.........................................................................................................................................................................1876 6.1.1 Overview - Haldex Clutch, Generation V.....................................................................................................................................................1876 6.2 Function, Checking...............................................................................................................................................................................1877 6.3 Haldex Clutch Pump -V181-, Removing and Installing...............................................................................................................................................1877 6.3.1 Haldex Clutch Pump -V181-, Removing and Installing, Generation V...........................................................................................................................1877 6.4 Haldex Clutch, Removing and Installing...........................................................................................................................................................1879 6.4.1 Haldex Clutch, Removing and Installing, Generation V.......................................................................................................................................1879 6.5 Control Module, Removing and Installing..........................................................................................................................................................1883 6.5.1 AWD Control Module -J492-, Removing and Installing, Generation V...........................................................................................................................1883 7 Driveshaft.............................................................................................................................................................................................1885 7.1 Overview - Driveshaft............................................................................................................................................................................1885 7.2 Driveshaft, Removing and Installing..............................................................................................................................................................1886 7.3 Front Flexible Disc, Removing and Installing.....................................................................................................................................................1889 7.4 Rear Flexible Disc, Removing and Installing......................................................................................................................................................1890 8 Special Tools..........................................................................................................................................................................................1895 9 Revision History.......................................................................................................................................................................................1901 04-Automatic Transmission & DSG.pdf (p.1905-2036)....................................................................................................................................................................1905 00 – General, Technical Data.....................................................................................................................................................................................1909 1 Safety Precautions.........................................................................................................................................................................................1909 1.1 General Safety Precautions...........................................................................................................................................................................1909 1.2 Start/Stop System Safety Precautions.................................................................................................................................................................1909 1.3 Towing Notes.........................................................................................................................................................................................1910 1.4 Road Test with Testing Equipment Safety Precautions..................................................................................................................................................1910 2 Identification.............................................................................................................................................................................................1911 2.1 Transmission Identification..........................................................................................................................................................................1911 2.1.1 Identification on Transmission.................................................................................................................................................................1911 2.1.2 Transmission Code Letters, Reading.............................................................................................................................................................1912 3 Repair Information.........................................................................................................................................................................................1914 3.1 General Repair Information...........................................................................................................................................................................1914 3.2 Seals, Sealing Rings.................................................................................................................................................................................1915 3.3 Bolts and Nuts.......................................................................................................................................................................................1915 4 Technical Data.............................................................................................................................................................................................1916 4.1 Capacities...........................................................................................................................................................................................1916 4.2 Transmission/Engine Allocation.......................................................................................................................................................................1916 4.3 Gear Ratio Calculation...............................................................................................................................................................................1916 5 Electrical Components......................................................................................................................................................................................1918 5.1 Component Location Overview - Transmission Control Module............................................................................................................................................1918 30 – Clutch......................................................................................................................................................................................................1919 1 Clutch.....................................................................................................................................................................................................1919 1.1 Overview - Dual Clutch...............................................................................................................................................................................1919 1.2 Clutch End Cover, Removing and Installing............................................................................................................................................................1921 1.3 Dual Clutch, Removing................................................................................................................................................................................1925 1.4 Dual Clutch, Installing..............................................................................................................................................................................1927 2 Special Tools..............................................................................................................................................................................................1932 34 – Controls, Housing...........................................................................................................................................................................................1933 1 Mechatronic................................................................................................................................................................................................1933 1.1 Overview - Mechatronic...............................................................................................................................................................................1933 1.2 Oil Pan, Removing and Installing.....................................................................................................................................................................1935 1.3 Mechatronic, Removing and Installing.................................................................................................................................................................1937 2 Bevel Box..................................................................................................................................................................................................1944 2.1 Overview - Flange Shafts and Seals on Bevel Box......................................................................................................................................................1944 2.2 Bevel Box, Removing..................................................................................................................................................................................1946 2.3 Bevel Box, Installing................................................................................................................................................................................1948 2.4 Right Seal, Replacing, for Flange Shaft on the Bevel Box.............................................................................................................................................1949 2.5 Seal, Replacing, between the Transmission and Bevel Box, on Bevel Box................................................................................................................................1950 2.6 Seal, Replacing for Driveshaft Output Flange on Bevel Box............................................................................................................................................1951 2.7 Right Flange Shaft, Removing and Installing..........................................................................................................................................................1954 2.8 Flange Shaft, Disassembling and Assembling...........................................................................................................................................................1955 2.9 Right Flange Shaft Needle Bearing (Polygon Bearing), Removing and Installing.........................................................................................................................1957 2.10 Axle Oil in Bevel Box, Installing...................................................................................................................................................................1957 2.11 Gear Oil in Bevel Box, Filling......................................................................................................................................................................1958 3 Selector Mechanism.........................................................................................................................................................................................1962 3.1 Overview - Selector Mechanism........................................................................................................................................................................1962 3.1.1 Overview - Selector Mechanism, ZF..............................................................................................................................................................1962 3.1.2 Overview - Selector Mechanism, ECS.............................................................................................................................................................1964 3.2 Emergency Release from P.............................................................................................................................................................................1965 3.2.1 Emergency Release from P, ZF...................................................................................................................................................................1965 3.2.2 Emergency Release from P, ECS..................................................................................................................................................................1966 3.3 Selector Lever Handle, Removing and Installing.......................................................................................................................................................1966 3.4 Button in Handle, Moving Into Installation Position..................................................................................................................................................1968 3.5 Selector Mechanism, Removing and Installing..........................................................................................................................................................1970 3.5.1 Shift Mechanism with Selector Lever Cable, Removing and Installing.............................................................................................................................1970 3.5.2 Gearshift Mechanism without Selector Lever Cable, Removing and Installing, ZF..................................................................................................................1972 3.5.3 Gearshift Mechanism without Selector Lever Cable, Removing and Installing, ECS.................................................................................................................1974 3.6 Selector Lever Cable, Removing and Installing........................................................................................................................................................1976 3.6.1 Selector Lever Cable, Removing and Installing, ZF..............................................................................................................................................1976 3.6.2 Selector Lever Cable, Removing and Installing, ECS.............................................................................................................................................1978 3.7 Selector Mechanism, Checking.........................................................................................................................................................................1980 3.8 Selector Lever Cable, Checking and Adjusting.........................................................................................................................................................1981 3.9 Selector Shaft Seal, Replacing.......................................................................................................................................................................1982 4 Transmission, Removing and Installing......................................................................................................................................................................1985 4.1 Transmission, Removing...............................................................................................................................................................................1985 4.2 Transmission, Installing.............................................................................................................................................................................1990 4.3 Transmission Tightening Specifications...............................................................................................................................................................1993 5 Subframe Mount.............................................................................................................................................................................................1994 5.1 Overview - Subframe Mount............................................................................................................................................................................1994 6 Transmission, Transporting.................................................................................................................................................................................1997 6.1 Transmission, Transporting...........................................................................................................................................................................1997 7 Transmission, Disassembling and Assembling.................................................................................................................................................................1998 7.1 Overview - Transmission..............................................................................................................................................................................1998 8 Securing on Engine and Transmission Holder.................................................................................................................................................................2001 8.1 Securing on Engine and Transmission Holder...........................................................................................................................................................2001 9 Transmission Fluid Circuit.................................................................................................................................................................................2002 9.1 Transmission Fluid Cooler, Removing and Installing...................................................................................................................................................2002 9.2 Transmission Fluid Pump Cover, Removing and Installing...............................................................................................................................................2004 9.3 Transmission Fluid Pump, Removing and Installing.....................................................................................................................................................2006 9.4 Transmission Fluid Filter, Removing and Installing...................................................................................................................................................2007 10 Transmission Fluid........................................................................................................................................................................................2010 10.1 Transmission Fluid Level, Checking..................................................................................................................................................................2010 10.2 Transmission Fluid, Draining and Filling............................................................................................................................................................2012 11 Special Tools.............................................................................................................................................................................................2016 35 – Gears, Shafts...............................................................................................................................................................................................2026 1 No Repairs to Gears and Shafts.............................................................................................................................................................................2026 39 – Final Drive, Differential...................................................................................................................................................................................2027 1 Seals......................................................................................................................................................................................................2027 1.1 Component Location Overview - Seals..................................................................................................................................................................2027 1.2 Left Flange Shaft Seal on Transmission...............................................................................................................................................................2028 1.3 Right Seal between Transmission and Bevel Box on Transmission, Replacing, AWD........................................................................................................................2030 2 Haldex Clutch, Checking Function...........................................................................................................................................................................2032 3 Driveshaft and Rear Final Drive............................................................................................................................................................................2033 4 Special Tools..............................................................................................................................................................................................2034 5 Revision History...........................................................................................................................................................................................2036 05-Steering & Suspension.pdf (p.2037-2681)...........................................................................................................................................................................2037 05-01 Suspension,Wheels & Steering...............................................................................................................................................................................2037 00 – General, Technical Data.................................................................................................................................................................................2043 1 Safety Precautions.....................................................................................................................................................................................2043 1.1 Safety Precautions when Working on Vehicles with Start/Stop System...............................................................................................................................2043 1.2 Safety Precautions when Working on Subframe......................................................................................................................................................2043 2 Repair Information.....................................................................................................................................................................................2044 2.1 Shock Absorber Leaks.............................................................................................................................................................................2044 2.2 Shock Absorber Noises............................................................................................................................................................................2044 2.3 Shock Absorbers, Checking when Removed...........................................................................................................................................................2045 2.4 Steering Gear....................................................................................................................................................................................2045 2.5 Seals and Gaskets................................................................................................................................................................................2046 2.6 Bolts and Nuts...................................................................................................................................................................................2046 2.7 Electrical Components............................................................................................................................................................................2046 2.8 Wheel Bearing in Curb Weight Position, Lifting Vehicles with Coil Spring.........................................................................................................................2047 2.8.1 Wheel Bearing in Curb Weight, Lifting Vehicles with Coil Spring, Front Axle................................................................................................................2047 2.8.2 Wheel Bearing in Curb Weight, Rear Axle, Lifting Vehicles with Coil Spring.................................................................................................................2048 3 Vehicles Involved in Collisions, Evaluating............................................................................................................................................................2051 3.1 Collision Vehicle Evaluation Checklist...........................................................................................................................................................2051 4 Disposal...............................................................................................................................................................................................2053 4.1 Front Gas-Filled Shock Absorbers, Venting and Draining...........................................................................................................................................2053 4.1.1 Front Shock Absorbers, Venting and Emptying, Standard Shock Absorber.......................................................................................................................2053 4.1.2 Front Shock Absorbers, Venting and Emptying, DCC Shock Absorber............................................................................................................................2054 4.2 Rear Gas-Filled Shock Absorbers, Venting and Draining............................................................................................................................................2054 4.2.1 Rear Shock Absorbers, Venting and Emptying, Standard Shock Absorber........................................................................................................................2054 4.2.2 Rear Shock Absorbers, Venting and Emptying, DCC Shock Absorber.............................................................................................................................2055 5 Special Tools..........................................................................................................................................................................................2056 40 – Front Suspension........................................................................................................................................................................................2057 1 Front Axle.............................................................................................................................................................................................2057 1.1 Component Location Overview - Front Axle.........................................................................................................................................................2057 2 Subframe...............................................................................................................................................................................................2058 2.1 Overview - Subframe..............................................................................................................................................................................2058 2.2 Subframe without Steering Gear, Removing and Installing..........................................................................................................................................2059 2.2.1 Subframe without Steering Gear, Removing and Installing, Except e-Golf.....................................................................................................................2059 2.2.2 Subframe without Steering Gear, Removing and Installing, e-Golf............................................................................................................................2063 2.3 Subframe with Steering Gear, Removing and Installing.............................................................................................................................................2066 2.3.1 Subframe with Steering Gear, Removing and Installing, except e-Golf........................................................................................................................2066 2.3.2 Subframe with Steering Gear, Removing and Installing, e-Golf...............................................................................................................................2071 2.3.3 Subframe with Steering Gear, Removing and Installing, RHD, except e-Golf...................................................................................................................2076 2.3.4 Subframe with Steering Gear, Removing and Installing, RHD, e-Golf..........................................................................................................................2082 2.4 Subframe, Servicing..............................................................................................................................................................................2087 2.5 Stabilizer Bar, Removing and Installing..........................................................................................................................................................2093 2.6 Coupling Rod, Removing and Installing............................................................................................................................................................2097 2.7 Thread in Longitudinal Member, Servicing.........................................................................................................................................................2098 2.8 Subframe, Securing...............................................................................................................................................................................2098 2.9 Subframe, Lowering...............................................................................................................................................................................2101 2.9.1 Subframe, Lowering, Except e-Golf..........................................................................................................................................................2101 2.9.2 Subframe, Lowering, e-Golf.................................................................................................................................................................2104 3 Suspension Strut and Upper Control Arm.................................................................................................................................................................2108 3.1 Overview - Suspension Strut and Upper Control Arm................................................................................................................................................2108 3.2 Suspension Strut, Removing and Installing........................................................................................................................................................2109 3.3 Suspension Strut, Servicing......................................................................................................................................................................2116 4 Lower Control Arm and Ball Joint.......................................................................................................................................................................2118 4.1 Overview - Lower Control Arm and Ball Joint......................................................................................................................................................2118 4.2 Lower Control Arm, Removing and Installing.......................................................................................................................................................2119 4.2.1 Lower Control Arm, Removing and Installing, Vehicles with Manual Transmission, DSG® Transmission 0CW.......................................................................................2119 4.2.2 Lower Control Arm, Removing and Installing, Vehicles with DSG® Transmission 0D9............................................................................................................2121 4.3 Ball Joint, Checking.............................................................................................................................................................................2124 4.4 Ball Joint, Removing and Installing..............................................................................................................................................................2125 4.5 Lower Control Arm Bonded Rubber Bushing, Replacing...............................................................................................................................................2128 4.5.1 Front Lower Control Arm Bonded Rubber Bushing, Replacing...................................................................................................................................2128 4.5.2 Lower Control Arm Rear Bonded Rubber Bushing, Replacing....................................................................................................................................2130 5 Wheel Bearing..........................................................................................................................................................................................2133 5.1 Overview - Wheel Bearing.........................................................................................................................................................................2133 5.2 Wheel Bearing Housing, Removing and Installing...................................................................................................................................................2133 5.3 Wheel Bearing Unit, Removing and Installing......................................................................................................................................................2138 6 Drive Axle.............................................................................................................................................................................................2142 6.1 Overview - Drive Axle............................................................................................................................................................................2142 6.2 Overview - Drive Axle............................................................................................................................................................................2143 6.2.1 Overview - Drive Axle, CV Joint VL 100.....................................................................................................................................................2143 6.2.2 Overview - Drive Axle, CV Joint VL 107.....................................................................................................................................................2145 6.2.3 Overview - Drive Axle, Triple Roller Joint AAR3300i........................................................................................................................................2147 6.3 Drive Axle, Removing and Installing..............................................................................................................................................................2148 6.3.1 Drive Axle, Removing and Installing, Left Drive Axle, CV Joint VL 100 and VL 107, Except e-Golf............................................................................................2148 6.3.2 Drive Axle, Removing and Installing, Right Drive Axle, CV Joint VL 100 and VL 107, Except e-Golf...........................................................................................2152 6.3.3 Drive Axle, Removing and Installing, Left Drive Axle, CV Joint VL 100 and VL 107, e-Golf...................................................................................................2156 6.3.4 Drive Axle, Removing and Installing, Right Drive Axle, CV Joint VL 100 and VL 107, e-Golf..................................................................................................2159 6.3.5 Drive Axle, Removing and Installing, Triple Roller Joint AAR3300i Attached.................................................................................................................2161 6.3.6 Drive Axle, Removing and Installing, Triple Roller Joint AAR3300i Bolted...................................................................................................................2165 6.4 Drive Axle Threaded Connection, Loosening and Tightening.........................................................................................................................................2169 6.5 Drive Axle Heat Shield, Removing and Installing..................................................................................................................................................2170 6.6 Drive Axle, Disassembling and Assembling.........................................................................................................................................................2171 6.6.1 Drive Axle, Disassembling and Assembling, CV Joint VL100...................................................................................................................................2171 6.6.2 Drive Axle, Disassembling and Assembling, CV Joint VL107...................................................................................................................................2174 6.6.3 Drive Axle, Disassembling and Assembling, Triple Roller Joint AAR3300i.....................................................................................................................2176 6.7 Outer CV Joint, Checking.........................................................................................................................................................................2180 6.8 Inner CV Joint, Checking.........................................................................................................................................................................2181 7 Special Tools..........................................................................................................................................................................................2183 42 – Rear Suspension.........................................................................................................................................................................................2198 1 Rear Axle..............................................................................................................................................................................................2198 1.1 Overview - Rear Axle.............................................................................................................................................................................2198 1.1.1 Overview - Rear Axle, Torsion Beam Axle....................................................................................................................................................2198 1.1.2 Overview - Rear Axle, Multi-Link Suspension................................................................................................................................................2199 1.1.3 Overview - Rear Axle, Multi-Link Suspension, AWD...........................................................................................................................................2201 1.2 Rear Axle, Lowering..............................................................................................................................................................................2202 1.2.1 Rear Axle, Lowering, Multi-link Suspension, FWD Except e-Golf..............................................................................................................................2202 1.2.2 Rear Axle, Lowering, Multi-link Suspension, FWD e-Golf.....................................................................................................................................2205 1.2.3 Rear Axle, Lowering, Multi-Link Suspension, AWD............................................................................................................................................2207 1.3 Rear Axle, Removing and Installing...............................................................................................................................................................2210 1.3.1 Rear Axle, Removing and Installing, Torsion Beam Axle......................................................................................................................................2210 1.3.2 Rear Axle, Removing and Installing, Multi-Link Suspension, FWD, except e-Golf and Golf GTE.................................................................................................2212 1.3.3 Rear Axle, Removing and Installing, Multi-Link Suspension, FWD e-Golf......................................................................................................................2215 1.3.4 Rear Axle, Removing and Installing, Multi-link Suspension, FWD, Golf GTE...................................................................................................................2219 1.3.5 Rear Axle, Removing and Installing, Multi-Link Suspension, AWD.............................................................................................................................2223 2 Axle Beam..............................................................................................................................................................................................2226 2.1 Overview - Axle Beam.............................................................................................................................................................................2226 2.2 Axle Beam Bonded Rubber Bushing, Replacing.......................................................................................................................................................2226 3 Subframe...............................................................................................................................................................................................2233 3.1 Overview - Subframe..............................................................................................................................................................................2233 3.1.1 Overview - Subframe, Multi-Link Suspension, FWD Except e-Golf..............................................................................................................................2233 3.1.2 Overview - Subframe, Multi-Link Suspension, FWD e-Golf.....................................................................................................................................2234 3.1.3 Overview - Subframe, Multi-Link Suspension, AWD............................................................................................................................................2235 3.2 Subframe, Securing...............................................................................................................................................................................2235 3.2.1 Subframe, Securing, Multi-Link Suspension, FWD, except e-Golf and Golf GTE.................................................................................................................2235 3.2.2 Subframe, Securing, Multi-Link Suspension, FWD e-Golf......................................................................................................................................2239 3.2.3 Subframe, Securing, Multi-link Suspension, FWD, Golf GTE...................................................................................................................................2244 3.2.4 Subframe, Securing, Multi-Link Suspension, AWD.............................................................................................................................................2248 3.3 Subframe, Servicing..............................................................................................................................................................................2251 3.3.1 Front Bonded Rubber Bushing, Replacing.....................................................................................................................................................2251 3.3.2 Rear Bonded Rubber Bushing, Replacing......................................................................................................................................................2257 4 Stabilizer Bar.........................................................................................................................................................................................2263 4.1 Overview - Stabilizer Bar........................................................................................................................................................................2263 4.1.1 Overview - Stabilizer Bar, Multi-Link Suspension, FWD......................................................................................................................................2263 4.1.2 Overview - Stabilizer Bar, Multi-Link Suspension, AWD......................................................................................................................................2264 4.2 Stabilizer Bar, Removing and Installing..........................................................................................................................................................2264 4.3 Coupling Rod, Removing and Installing............................................................................................................................................................2265 5 Control Arm, Tie Rod...................................................................................................................................................................................2268 5.1 Overview - Transverse Link.......................................................................................................................................................................2268 5.1.1 Overview - Transverse Link, Multi-Link Suspension, FWD.....................................................................................................................................2268 5.1.2 Overview - Transverse Link, Multi-Link Suspension, AWD.....................................................................................................................................2270 5.2 Overview - Tie Rod...............................................................................................................................................................................2272 5.2.1 Overview - Tie Rod, Multi-Link Suspension, FWD.............................................................................................................................................2272 5.2.2 Overview - Tie Rod, Multi-Link Suspension, AWD.............................................................................................................................................2273 5.3 Upper Transverse Link, Removing and Installing...................................................................................................................................................2273 5.3.1 Upper Transverse Link, Removing and Installing, FWD........................................................................................................................................2273 5.3.2 Upper Transverse Link, Removing and Installing, AWD........................................................................................................................................2274 5.4 Lower Transverse Link, Removing and Installing...................................................................................................................................................2275 5.5 Tie Rod, Removing and Installing.................................................................................................................................................................2277 6 Suspension Strut/Shock Absorber, Spring................................................................................................................................................................2279 6.1 Overview - Suspension Strut, Shock Absorber and Spring...........................................................................................................................................2279 6.1.1 Overview - Suspension Strut, Shock Absorber and Spring, Torsion Beam Axle..................................................................................................................2279 6.1.2 Overview - Suspension Strut, Shock Absorber and Spring, Multi-Link Suspension..............................................................................................................2280 6.2 Shock Absorber, Removing and Installing..........................................................................................................................................................2281 6.2.1 Shock Absorber, Removing and Installing, Torsion Beam Axle.................................................................................................................................2281 6.2.2 Shock Absorber, Removing and Installing, Multi-Link Suspension, Left Shock Absorber........................................................................................................2283 6.2.3 Shock Absorber, Removing and Installing, Multi-Link Suspension, Right Shock Absorber.......................................................................................................2285 6.3 Shock Absorber, Servicing........................................................................................................................................................................2288 6.4 Spring, Removing and Installing..................................................................................................................................................................2290 6.4.1 Spring, Removing and Installing, Torsion Beam Axle.........................................................................................................................................2290 6.4.2 Spring, Removing and Installing, Multi-Link Suspension, Left Spring FWD, Left and Right Spring AWD.........................................................................................2292 6.4.3 Spring, Removing and Installing, Multi-Link Suspension, Right Spring, FWD..................................................................................................................2294 7 Wheel Bearing and Trailing Arm.........................................................................................................................................................................2299 7.1 Overview - Wheel Bearing.........................................................................................................................................................................2299 7.1.1 Overview - Wheel Bearing, Torsion Beam Axle................................................................................................................................................2299 7.1.2 Overview - Wheel Bearing, Multi-Link Suspension, FWD.......................................................................................................................................2301 7.1.3 Overview - Wheel Bearing, Multi-Link Suspension, AWD.......................................................................................................................................2302 7.2 Overview - Trailing Arm..........................................................................................................................................................................2303 7.2.1 Overview - Trailing Arm, Except e-Golf.....................................................................................................................................................2303 7.2.2 Overview - Trailing Arm, e-Golf............................................................................................................................................................2304 7.3 Wheel Bearing Housing, Removing and Installing...................................................................................................................................................2304 7.3.1 Wheel Bearing Housing, Removing and Installing, Multi-Link Suspension, FWD.................................................................................................................2304 7.3.2 Wheel Bearing Housing, Removing and Installing, Multi-Link Suspension, AWD.................................................................................................................2308 7.4 Wheel Bearing Unit, Removing and Installing......................................................................................................................................................2313 7.4.1 Wheel Bearing Unit, Removing and Installing, Torsion Beam Axle.............................................................................................................................2313 7.4.2 Wheel Bearing Unit, Removing and Installing, Multi-Link Suspension, FWD....................................................................................................................2315 7.4.3 Wheel Bearing Unit, Removing and Installing, Multi-Link Suspension, AWD....................................................................................................................2318 7.5 Wheel Bearing Housing Bonded Rubber Bushing, Replacing...........................................................................................................................................2320 7.5.1 Wheel Bearing Housing Bonded Rubber Bushing, Replacing, FWD................................................................................................................................2320 7.5.2 Wheel Bearing Housing Bonded Rubber Bushing, Replacing, AWD................................................................................................................................2322 7.6 Trailing Arm with Mounting Bracket, Removing and Installing......................................................................................................................................2325 7.6.1 Trailing Arm with Mounting Bracket, Removing and Installing, Except e-Golf.................................................................................................................2325 7.6.2 Trailing Arm with Mounting Bracket, Removing and Installing, e-Golf........................................................................................................................2328 7.7 Trailing Arm, Servicing..........................................................................................................................................................................2331 8 Drive Axle.............................................................................................................................................................................................2334 8.1 Overview - Drive Axle............................................................................................................................................................................2334 8.2 Drive Axle, Removing and Installing..............................................................................................................................................................2335 8.3 Drive Axle, Disassembling and Assembling.........................................................................................................................................................2339 8.4 Drive Axle Threaded Connection, Loosening and Tightening.........................................................................................................................................2342 8.5 Outer CV Joint, Checking.........................................................................................................................................................................2343 8.6 Inner CV Joint, Checking.........................................................................................................................................................................2345 9 Special Tools..........................................................................................................................................................................................2347 43 – Self-Leveling Suspension................................................................................................................................................................................2359 1 Electronic Damping.....................................................................................................................................................................................2359 1.1 Overview - Electronic Damping....................................................................................................................................................................2359 1.1.1 Overview - Electronic Damping, Torsion Beam Axle, Sedan....................................................................................................................................2359 1.1.2 Overview - Electronic Damping, Multi-Link Suspension, Sedan................................................................................................................................2361 1.1.3 Overview - Electronic Damping, Multi-Link Suspension, Wagon................................................................................................................................2363 1.2 Electronic Damping Control Module -J250-, Removing and Installing................................................................................................................................2364 1.2.1 Electronic Damping Control Module -J250-, Removing and Installing, Sedan...................................................................................................................2364 1.2.2 Electronic Damping Control Module -J250-, Removing and Installing, Wagon...................................................................................................................2365 1.3 Left/Right Front Body Acceleration Sensor - G341-/-G342-, Removing and Installing................................................................................................................2366 1.4 Rear Body Acceleration Sensor -G343-, Removing and Installing....................................................................................................................................2367 2 Level Control System Sensor............................................................................................................................................................................2369 2.1 Overview - Front Level Control System Sensor.....................................................................................................................................................2369 2.2 Overview - Rear Level Control System Sensor......................................................................................................................................................2370 2.2.1 Overview - Rear Level Control System Sensor, Torsion Beam Axle.............................................................................................................................2370 2.2.2 Overview - Rear Level Control System Sensor, Multi-Link Suspension, FWD....................................................................................................................2371 2.2.3 Overview - Rear Level Control System Sensor, Multi-Link Suspension, AWD....................................................................................................................2372 2.3 Left/Right Front Level Control System Sensor -G78-/-G289-, Removing and Installing...............................................................................................................2372 2.4 Left/Right Rear Level Control System Sensor - G76-/-G77-, Removing and Installing................................................................................................................2374 2.4.1 Left Rear Level Control System Sensor -G76-, Removing and Installing, Torsion Beam Axle....................................................................................................2374 2.4.2 Left Rear Level Control System Sensors -G76-, Removing and Installing, Multi-Link Suspension, FWD..........................................................................................2374 2.4.3 Left Rear Level Control System Sensors -G76-, Removing and Installing, Multi-Link Suspension, AWD..........................................................................................2375 3 Special Tools..........................................................................................................................................................................................2376 44 – Wheels, Tires, Wheel Alignment..........................................................................................................................................................................2377 1 Wheels and Tires.......................................................................................................................................................................................2377 1.1 Tires, Dismounting...............................................................................................................................................................................2377 1.2 Tires, Mounting..................................................................................................................................................................................2377 1.3 Wheel, Changing..................................................................................................................................................................................2378 1.3.1 Wheel Changing, Protecting Wheel Centering Seat Against Corrosion..........................................................................................................................2378 1.3.2 Wheel, Changing............................................................................................................................................................................2379 1.3.3 Wheel Changing Instructions................................................................................................................................................................2380 1.3.4 Wheel Changing and Wheel Installation......................................................................................................................................................2381 1.3.5 Wheel Changing, Position of Anti-Theft Wheel Bolts on Steel Wheels.........................................................................................................................2381 1.4 Wheel Bolt Tightening Specifications.............................................................................................................................................................2382 1.5 Tires, Dismounting...............................................................................................................................................................................2382 1.6 Tire Sealant, Disposing..........................................................................................................................................................................2383 1.7 Vehicles with Tire Mobility Kit..................................................................................................................................................................2383 1.7.1 Vehicles with Break-Down Kit, Sedan........................................................................................................................................................2383 1.7.2 Vehicles with Break-Down Kit, Wagon........................................................................................................................................................2384 2 Tire Pressure Monitoring System........................................................................................................................................................................2385 2.1 System Description - Tire Pressure Monitoring System.............................................................................................................................................2385 3 Vehicle Alignment......................................................................................................................................................................................2387 3.1 Axle Alignment Information.......................................................................................................................................................................2387 3.2 Test Requirements................................................................................................................................................................................2387 3.3 Measure Preparations.............................................................................................................................................................................2388 3.3.1 Measurement Preparations, Axle Alignment without Driver Assistance Systems.................................................................................................................2388 3.3.2 Measurement Preparations, Axle Alignment with Driver Assistance Systems....................................................................................................................2389 3.4 Axle Alignment Specified Values..................................................................................................................................................................2389 3.4.1 Axle Alignment Specified Values, Torsion Beam Axle, Golf...................................................................................................................................2389 3.4.2 Axle Alignment Specified Values, Torsion Beam Axle, Golf Wagon.............................................................................................................................2391 3.4.3 Axle Alignment Specified Values, Multi-Link Suspension, Golf...............................................................................................................................2392 3.4.4 Axle Alignment Specified Values, Multi-Link Suspension, Golf Wagon, Golf Wagon R, Golf Alltrack............................................................................................2395 3.4.5 Axle Alignment Specified Values, Multi-Link Suspension, e-Golf.............................................................................................................................2396 3.5 Vehicle, Preparing for Aligning..................................................................................................................................................................2397 3.6 Axle Alignment Procedure.........................................................................................................................................................................2397 3.7 Need for Axle Alignment, Evaluating..............................................................................................................................................................2399 3.7.1 Evaluating Need for Axle Alignment, Torsion Beam Axle......................................................................................................................................2399 3.7.2 Evaluating Need for Axle Alignment, Multi-Link Suspension..................................................................................................................................2400 3.8 Front Axle Camber, Adjusting.....................................................................................................................................................................2401 3.9 Rear Axle Camber, Adjusting......................................................................................................................................................................2402 3.9.1 Rear Axle Camber, Adjusting, Torsion Beam Axle.............................................................................................................................................2402 3.9.2 Rear Axle Camber, Adjusting, Multi-Link Suspension.........................................................................................................................................2402 3.10 Rear Axle Toe, Adjusting........................................................................................................................................................................2403 3.10.1 Rear Axle Toe, Adjusting, Torsion Beam Axle...............................................................................................................................................2403 3.10.2 Rear Axle Toe, Adjusting, Multi-Link Suspension...........................................................................................................................................2403 3.11 Front Axle Toe, Adjusting.......................................................................................................................................................................2404 3.12 Wheel Run-Out Compensation......................................................................................................................................................................2405 3.13 Vehicle Data Label..............................................................................................................................................................................2405 3.14 Maximum Steering Angle, Checking................................................................................................................................................................2405 4 Wheel/Tire Vibration, Causes and Solution..............................................................................................................................................................2407 4.1 Vibration Causes.................................................................................................................................................................................2407 4.2 Road Test, Performing Before Balancing...........................................................................................................................................................2407 4.3 Wheel, Balancing.................................................................................................................................................................................2408 4.3.1 Wheel, Balancing...........................................................................................................................................................................2408 4.3.2 Wheel, Balancing on Stationary Balancing Machine...........................................................................................................................................2408 4.3.3 Wheel, Balancing with Fine Balancing Machine (Finish Balancer).............................................................................................................................2411 4.4 Vibration Control System.........................................................................................................................................................................2412 4.5 Tire and Wheel Radial and Lateral Run-Out, Checking..............................................................................................................................................2412 4.5.1 Tire and Wheel Radial and Lateral Run-Out, Checking, Tolerances............................................................................................................................2412 4.5.2 Wheels and Tires, Radial and Lateral Run Out, Checking with Tire Dial Gauge................................................................................................................2413 4.6 Rim Radial and Lateral Run-Out, Checking.........................................................................................................................................................2413 4.7 Wheels and Tires, Matching.......................................................................................................................................................................2414 4.8 Flat Spots in Tires From Standing, Determining...................................................................................................................................................2415 5 Adaptive Cruise Control (ACC)..........................................................................................................................................................................2417 5.1 Adaptive Cruise Control (ACC), Calibrating.......................................................................................................................................................2417 5.1.1 Adaptive Cruise Control (ACC), Calibrating, Except e-Golf..................................................................................................................................2417 5.1.2 Adaptive Cruise Control (ACC), Calibrating, e-Golf.........................................................................................................................................2423 6 Driver Assistance Systems Front Camera.................................................................................................................................................................2429 6.1 Driver Assistance Systems Front Camera, Calibrating..............................................................................................................................................2429 7 Special Tools..........................................................................................................................................................................................2436 48 – Steering................................................................................................................................................................................................2438 1 Steering Wheel.........................................................................................................................................................................................2438 1.1 Overview - Steering Wheel........................................................................................................................................................................2438 1.2 Steering Wheel, Removing and Installing..........................................................................................................................................................2438 2 Steering Column........................................................................................................................................................................................2440 2.1 Overview - Steering Column.......................................................................................................................................................................2440 2.2 Steering Column, Checking for Damage.............................................................................................................................................................2441 2.3 Steering Column, Handling and Transporting.......................................................................................................................................................2441 2.4 Steering Column, Removing and Installing.........................................................................................................................................................2442 2.4.1 Steering Column, Removing and Installing...................................................................................................................................................2442 2.4.2 Steering Column, Removing and Installing, RHD..............................................................................................................................................2450 2.5 Electronic Steering Column Lock Control Module -J764-, Removing and Installing...................................................................................................................2459 3 Steering Gear..........................................................................................................................................................................................2461 3.1 Overview - Steering Gear.........................................................................................................................................................................2461 3.1.1 Overview - Steering Gear...................................................................................................................................................................2461 3.1.2 Overview - Steering Gear, RHD..............................................................................................................................................................2463 3.2 Steering Gear, Removing and Installing...........................................................................................................................................................2464 3.2.1 Steering Gear, Removing and Installing, except e-Golf......................................................................................................................................2464 3.2.2 Steering Gear, Removing and Installing, e-Golf.............................................................................................................................................2470 3.2.3 Steering Gear, Removing and Installing, RHD, except e-Golf.................................................................................................................................2476 3.2.4 Steering Gear, Removing and Installing, RHD e-Golf.........................................................................................................................................2483 3.3 Boot, Removing and Installing....................................................................................................................................................................2490 3.4 Tie Rod, Removing and Installing.................................................................................................................................................................2492 3.5 Tie Rod End, Removing and Installing.............................................................................................................................................................2494 3.6 Steering Gear, Servicing.........................................................................................................................................................................2495 4 Sensors................................................................................................................................................................................................2498 4.1 Steering Angle Sensor -G85-, Removing and Installing.............................................................................................................................................2498 5 Special Tools..........................................................................................................................................................................................2499 6 Revision History.......................................................................................................................................................................................2502 05-02 Wheel and Tire Guide General Information...................................................................................................................................................................2506 44 – Wheels, Tires, Wheel Alignment..........................................................................................................................................................................2510 1 Specifications for Retrofitting Wheel and Tire Combinations............................................................................................................................................2510 1.1 Legal Requirements...............................................................................................................................................................................2510 1.1.1 Permitted Wheel and Tire Combinations in Germany...........................................................................................................................................2510 1.1.2 Vehicles with Tire Pressure Monitoring System..............................................................................................................................................2510 1.2 Technical Requirements...........................................................................................................................................................................2511 1.3 Load Rating Depending on Speed and Winter Tires..................................................................................................................................................2511 1.4 Vehicle Registration Documents Since 01/10/2005..................................................................................................................................................2513 1.5 Certificate of Conformity........................................................................................................................................................................2514 1.6 EU Type Approval Number, Sales Code and Sales or Trade Name......................................................................................................................................2514 2 Handling Problems......................................................................................................................................................................................2516 2.1 Driving Noise....................................................................................................................................................................................2516 2.1.1 Tires, Rolling Noises, General Information.................................................................................................................................................2516 2.1.2 Wear Spots.................................................................................................................................................................................2517 2.2 Vehicle Pulls to One Side........................................................................................................................................................................2517 2.2.1 General Information........................................................................................................................................................................2517 2.2.2 Taper......................................................................................................................................................................................2518 2.2.3 Corrective Action When Vehicle Pulls to One Side...........................................................................................................................................2519 2.2.4 Targeted Rotating of Wheels for Non-Directional Tires......................................................................................................................................2520 2.2.5 Wheels, Targeted Rotating for Directional Tires............................................................................................................................................2521 2.3 Vibration........................................................................................................................................................................................2522 2.3.1 Vibration, Causes for Vibration............................................................................................................................................................2522 2.3.2 Vibration, Road Test, Performing Before Balancing..........................................................................................................................................2522 2.3.3 Vibration, Vibration Control System........................................................................................................................................................2523 2.4 Flat Spots, Correcting...........................................................................................................................................................................2523 3 Tires, Evaluating......................................................................................................................................................................................2524 3.1 Flat Spots.......................................................................................................................................................................................2524 3.2 Cracking.........................................................................................................................................................................................2524 3.3 Heel and Toe Wear................................................................................................................................................................................2525 3.4 Wear Spots.......................................................................................................................................................................................2525 3.5 Tire Sidewall Swelling...........................................................................................................................................................................2525 3.6 Cuts.............................................................................................................................................................................................2527 3.7 Foreign Object Damage............................................................................................................................................................................2527 3.8 Disintegrated Tread..............................................................................................................................................................................2527 3.9 Tires, Damage from Low Tire Pressure.............................................................................................................................................................2528 3.10 Inspecting Tires................................................................................................................................................................................2528 3.11 Mounting Damage.................................................................................................................................................................................2529 4 Tire Wear..............................................................................................................................................................................................2531 4.1 Tire Service Life, Influences....................................................................................................................................................................2531 4.2 Heel and Toe Wear................................................................................................................................................................................2532 4.3 High Speed Tires, Wear Characteristics...........................................................................................................................................................2532 4.4 Tread Depth, Measuring...........................................................................................................................................................................2533 4.5 Tire Wear, One Sided.............................................................................................................................................................................2533 4.6 Tire Wear, Outer Shoulder........................................................................................................................................................................2536 4.7 Diagonal Washouts................................................................................................................................................................................2537 4.8 Tire Wear, Center................................................................................................................................................................................2537 4.9 Permitted Tread Depth - Variance.................................................................................................................................................................2538 5 Component Overview.....................................................................................................................................................................................2539 5.1 Overview - Wheel.................................................................................................................................................................................2539 5.1.1 Overview - Wheel, Standard.................................................................................................................................................................2539 5.1.2 Overview - Wheel, RAX......................................................................................................................................................................2540 6 Tires, Mounting........................................................................................................................................................................................2542 6.1 Tires, Dismounting...............................................................................................................................................................................2542 6.2 Tire Sealant, Removing...........................................................................................................................................................................2542 6.3 Tires, Dismounting...............................................................................................................................................................................2543 6.3.1 Tires, Dismounting, Wheels without and with Tire Pressure Monitoring System................................................................................................................2543 6.3.2 Tires, Dismounting, Run-Flat Tires and Ultra High Performance Tires........................................................................................................................2544 6.4 Tires, Bringing to Mounting Temperature..........................................................................................................................................................2546 6.5 Tires, Mounting..................................................................................................................................................................................2546 6.5.1 Tires, Mounting, Wheels without and with Tire Pressure Monitoring System...................................................................................................................2546 6.5.2 Tires, Mounting, Run-Flat Tires and Ultra High Performance Tires...........................................................................................................................2548 6.6 Tires and Rims, Matching.........................................................................................................................................................................2550 6.7 Wheel, Balancing.................................................................................................................................................................................2551 6.7.1 Wheel, Balancing on Stationary Balancing Machine...........................................................................................................................................2551 6.7.2 Wheel, Balancing with Fine Balancing Machine (Finish Balancer).............................................................................................................................2554 6.7.3 Wheel, Balancing, Tire and Wheel Radial and Lateral Run-Out, Checking......................................................................................................................2555 6.7.4 Wheel Balancing, Rim Radial and Lateral Run-Out, Checking..................................................................................................................................2557 7 Wheel, Mounting........................................................................................................................................................................................2558 7.1 Wheel, Mounting..................................................................................................................................................................................2558 7.1.1 Wheel, Mounting, Volkswagen Assembly Instructions..........................................................................................................................................2558 7.1.2 Wheel, Mounting, Audi Assembly Instructions................................................................................................................................................2561 7.1.3 Wheel Mounting, Position of Anti-Theft Wheel Bolts on Steel Wheels.........................................................................................................................2567 8 Tire Information.......................................................................................................................................................................................2568 8.1 Side Wall Lettering..............................................................................................................................................................................2568 8.1.1 Side Wall Lettering, Standard Tire.........................................................................................................................................................2568 8.1.2 Run-Flat Tire (PAX), Lettering On Side Wall................................................................................................................................................2570 8.2 Tire Dimension...................................................................................................................................................................................2570 8.3 Load index (LI)..................................................................................................................................................................................2571 8.4 Speed Rating.....................................................................................................................................................................................2571 8.5 EU Tire Label....................................................................................................................................................................................2572 8.5.1 EU Tire Label, Short Overview..............................................................................................................................................................2572 8.5.2 EU Tire Label, Goals.......................................................................................................................................................................2573 8.5.3 EU Tire Label, Categories..................................................................................................................................................................2574 8.6 Overview - Radial Ply Tire.......................................................................................................................................................................2577 8.6.1 Cross-Section of a Radial Ply Tire.........................................................................................................................................................2577 8.6.2 Run-Flat Tire, Structure and Identification, SST Tire......................................................................................................................................2578 8.6.3 Run-Flat Tire, Seal Inside-Technology......................................................................................................................................................2579 8.6.4 Run-Flat Tire, Overview of a PAX Tire......................................................................................................................................................2581 8.7 Tires with Emergency Running Characteristics, SST (Self-Supporting Tire).........................................................................................................................2583 8.7.1 Run-Flat Tire, General Information.........................................................................................................................................................2583 8.7.2 Run-Flat Tire, Retrofitting/Conditions for use of Run-Flat Tires...........................................................................................................................2584 8.7.3 Run-Flat Tire, Repair......................................................................................................................................................................2585 8.8 Run-Flat Tire PAX................................................................................................................................................................................2585 8.8.1 Run-Flat Tire PAX, Tire Inflation..........................................................................................................................................................2585 8.8.2 Run-Flat Tire PAX, Wheel Alignment and Adjustment..........................................................................................................................................2586 8.8.3 Run-Flat Tire PAX, Repairing...............................................................................................................................................................2586 8.8.4 Run-Flat Tire PAX, Examining...............................................................................................................................................................2586 8.9 Tires, Storing...................................................................................................................................................................................2587 8.10 Tires, Reinforced, Extra Load...................................................................................................................................................................2588 8.11 Winter tires....................................................................................................................................................................................2588 8.12 Winter Tires with Speed Symbol V................................................................................................................................................................2590 8.13 Rolling Resistance Tires........................................................................................................................................................................2591 8.14 Tires, Aging....................................................................................................................................................................................2591 8.15 Tires with Rim Protector........................................................................................................................................................................2592 8.16 Tire Sizes, AWD Vehicles........................................................................................................................................................................2593 8.17 Increasing Temperature Due To Low Tire Pressure.................................................................................................................................................2593 9 Rim Information........................................................................................................................................................................................2594 9.1 Overview - Rim...................................................................................................................................................................................2594 9.2 Identification...................................................................................................................................................................................2595 9.3 Composite Wheels.................................................................................................................................................................................2595 9.4 Light Alloy Wheels, Care and Maintenance.........................................................................................................................................................2595 9.5 Light Alloy Wheels, Preparing....................................................................................................................................................................2596 9.6 Hub Cap for Alloy Wheels with Open Threaded Connection, Removing and Installing..................................................................................................................2597 9.7 Decorative Trims, Replacing......................................................................................................................................................................2597 9.7.1 Decorative Trims, Replacing, Bonded Decorative Trims.......................................................................................................................................2597 9.7.2 Decorative Trims, Replacing, Bolted Decorative Trims.......................................................................................................................................2600 9.8 Valve, Removing and Installing...................................................................................................................................................................2602 9.8.1 Valve, Removing and Installing, Valve Explanations.........................................................................................................................................2602 9.8.2 Valve, Removing and Installing, Rubber Valve...............................................................................................................................................2603 9.8.3 Valve, Removing and Installing, Metal Valve................................................................................................................................................2603 9.9 Run-Flat System PAX..............................................................................................................................................................................2604 9.9.1 Run-Flat System PAX, Support Ring..........................................................................................................................................................2604 9.9.3 Run-Flat System PAX, Examining Support Ring................................................................................................................................................2604 10 Tire Pressure Monitoring System.......................................................................................................................................................................2606 10.1 Tire Pressure Monitoring System.................................................................................................................................................................2606 10.2 Tire Pressure Monitoring System.................................................................................................................................................................2606 11 Tire Pressure Sensor..................................................................................................................................................................................2607 11.1 Overview - Tire Pressure Monitoring Sensor......................................................................................................................................................2607 11.1.1 Overview - Tire Pressure Monitoring Sensor with Valve.....................................................................................................................................2607 11.1.2 Overview - Tire Pressure Monitoring Sensor without Valve..................................................................................................................................2608 11.2 Tire Pressure Monitoring Sensor, Removing and Installing........................................................................................................................................2610 11.2.1 Tire Pressure Monitoring Sensor with Valve, Removing and Installing.......................................................................................................................2610 11.2.2 Tire Pressure Monitoring Sensor without Metal Valve, Removing and Installing, Service Version.............................................................................................2611 11.2.3 Tire Pressure Monitoring Sensor without Valve, Removing and Installing, Vehicle Before Customer Delivery..................................................................................2612 11.2.4 Tire Pressure Sensor and Metal Valve, Removing and Installing.............................................................................................................................2614 11.2.6 Siemens Wheel Electronics Tire Pressure Monitoring Sensor, Removing and Installing........................................................................................................2616 12 Tire Sealant..........................................................................................................................................................................................2617 12.1 Tire Sealant, Expiration Date...................................................................................................................................................................2617 12.2 Tire Sealant, Disposal..........................................................................................................................................................................2617 13 Wheel Bolts...........................................................................................................................................................................................2618 13.1 Wheel Bolt Versions.............................................................................................................................................................................2618 13.2 Wheel Bolts, Anti-Theft Wheel Bolt..............................................................................................................................................................2619 13.3 Wheel Bolts, Master Sets for Anti-Theft Wheel Bolts.............................................................................................................................................2619 14 Snow Chains...........................................................................................................................................................................................2621 14.1 Snow Chains, Assembly and Replacing.............................................................................................................................................................2621 15 Emergency Wheels......................................................................................................................................................................................2622 15.1 Spare Wheel Notes...............................................................................................................................................................................2622 16 Special Tools.........................................................................................................................................................................................2623 17 Revision History......................................................................................................................................................................................2625 05-03 Wheel and Tire Guide.......................................................................................................................................................................................2629 44 – Wheels, Tires, Wheel Alignment..........................................................................................................................................................................2633 1 General Information when Using Wheel and Tire Guide....................................................................................................................................................2633 1.1 General Information..............................................................................................................................................................................2633 1.2 Explanations about Regions.......................................................................................................................................................................2634 1.3 Tire Package Definition..........................................................................................................................................................................2635 1.4 Procedure to Find the Correct Tire Package.......................................................................................................................................................2635 2 Certificate of Registration Explanation................................................................................................................................................................2636 2.1 Certificate of Registration Section 1............................................................................................................................................................2636 2.2 Version Key (D2).................................................................................................................................................................................2636 2.2.1 Version Key (D2) Type Approval Number (K): e1*2007/46*0623*10..............................................................................................................................2636 2.2.2 Version Key (D2) Type Approval Number (K): e1*2007/46*0623*11 through e1*2007/46*0623*14...................................................................................................2637 2.2.3 Version Key (D2) from Type Approval Number (K): from e1*2007/46*0623*15....................................................................................................................2638 3 Wheel and Tire Combinations............................................................................................................................................................................2640 3.1 Golf 2013, from MY 2013, Sales Type 5G1..........................................................................................................................................................2640 3.2 Golf BlueMotion, from MY 2013, Sales Type 5G1....................................................................................................................................................2647 3.3 Golf GTD, from MY 2013, Sales Type 5G1...........................................................................................................................................................2648 3.4 Golf GTI, from MY 2013, Sales Type 5G1...........................................................................................................................................................2650 3.5 Golf R, from MY 2014, Sales Type 5G1.............................................................................................................................................................2652 4 Overview of Technically Possible Wheel and Tire Combinations depending on Tire Package.................................................................................................................2654 4.1 Type Approval Number (K): e1*2007/46*0623*10.....................................................................................................................................................2654 4.2 Type Approval Number (K): e1*2007/46*0623*11 through e1*2007/46*0623*14..........................................................................................................................2655 4.3 Type Approval Number (K): e1*2007/46*0623*15.....................................................................................................................................................2656 5 Wheel Allocation.......................................................................................................................................................................................2662 5.1 6 J x 15.........................................................................................................................................................................................2662 5.2 6 J x 16.........................................................................................................................................................................................2663 5.3 61/2 J x 16......................................................................................................................................................................................2664 5.4 6 J x 17.........................................................................................................................................................................................2665 5.5 7 J x 17.........................................................................................................................................................................................2666 5.6 71/2 J x 17......................................................................................................................................................................................2667 5.7 71/2 J x 18 ET 49................................................................................................................................................................................2668 5.8 71/2 J x 18 ET 51................................................................................................................................................................................2669 5.9 71/2 J x 19......................................................................................................................................................................................2670 5.10 8 J x 19........................................................................................................................................................................................2671 6 Recommended Summer Tires...............................................................................................................................................................................2673 6.1 Recommended Winter Tires, Worldwide except USA and Canada, China.................................................................................................................................2673 6.2 Recommended Summer Tires, Japan, South Korea, Indonesia and Singapore............................................................................................................................2673 7 Recommended All Season Tires...........................................................................................................................................................................2675 7.1 Recommended all-season tires, worldwide except USA and Canada, China.............................................................................................................................2675 7.2 Recommended All Season Tires, North America......................................................................................................................................................2675 8 Recommended Winter Tires, Worldwide except North America and China.....................................................................................................................................2676 9 Recommended Spare Tires and Emergency Wheels...........................................................................................................................................................2677 10 Revision History......................................................................................................................................................................................2678 06-Brake System.pdf (p.2682-2837)....................................................................................................................................................................................2682 00 – General, Technical Data.....................................................................................................................................................................................2686 1 Safety Precautions.........................................................................................................................................................................................2686 1.1 Safety Precautions during Road Test with Testing Equipment...........................................................................................................................................2686 2 Identification.............................................................................................................................................................................................2687 2.1 Brake PR Numbers.....................................................................................................................................................................................2687 2.1.1 Front Brakes...................................................................................................................................................................................2687 2.1.2 Rear Brakes....................................................................................................................................................................................2687 3 Technical Data.............................................................................................................................................................................................2689 3.1 Brakes Technical Data................................................................................................................................................................................2689 3.1.1 Brake Master Cylinder and Brake Booster........................................................................................................................................................2689 4 Brakes Inspection..........................................................................................................................................................................................2693 4.1 General Information..................................................................................................................................................................................2693 4.2 Front Wheel Drive Vehicles, Checking.................................................................................................................................................................2693 4.3 AWD Vehicles, Checking...............................................................................................................................................................................2693 4.3.1 Controlled Opposite-Running Test Stand.........................................................................................................................................................2693 4.3.2 Without Test Stand.............................................................................................................................................................................2694 4.4 Parking Brake, Checking..............................................................................................................................................................................2694 4.4.1 Electromechanical Parking Brake, Checking, FWD Vehicles........................................................................................................................................2694 4.4.2 Electromechanical Parking Brake, Checking, AWD Vehicles........................................................................................................................................2695 45 – Antilock Brake System.......................................................................................................................................................................................2696 1 General Information........................................................................................................................................................................................2696 1.1 ABS Repair Instructions..............................................................................................................................................................................2696 2 Component Location Overview................................................................................................................................................................................2699 2.1 Overview - ABS/ESP...................................................................................................................................................................................2699 3 Control Module and Hydraulic Unit..........................................................................................................................................................................2701 3.1 Overview - Control Module and Hydraulic Unit.........................................................................................................................................................2701 3.1.1 Overview - Control Module and Hydraulic Unit...................................................................................................................................................2701 3.1.2 Overview - Control Module and Hydraulic Unit, RHD..............................................................................................................................................2703 3.2 ABS Control Module -J104-/ABS Hydraulic Unit -N55-, Removing and Installing..........................................................................................................................2705 3.2.1 ABS Control Module and ABS Hydraulic Unit, Removing and Installing, LHD, Gasoline Engine.......................................................................................................2705 3.2.2 ABS Control Module and ABS Hydraulic Unit, Removing and Installing, LHD, Diesel Engine.........................................................................................................2708 3.2.3 Control Module and Hydraulic Unit, Removing and Installing, LHD, AWD Diesel Engine.............................................................................................................2713 3.2.4 ABS Control Module and ABS Hydraulic Unit, Removing and Installing.............................................................................................................................2719 3.2.5 ABS Control Module and ABS Hydraulic Unit, Removing and Installing, RHD........................................................................................................................2722 3.3 Control Module, Separating from Hydraulic Unit.......................................................................................................................................................2726 3.4 Control Module, Attaching to Hydraulic Unit..........................................................................................................................................................2727 3.5 Brake Lines, Attaching to Hydraulic Unit.............................................................................................................................................................2728 3.5.1 Brake Lines, Attaching to Hydraulic Unit.......................................................................................................................................................2728 3.5.2 Brake Lines, Attaching to Hydraulic Unit, RHD..................................................................................................................................................2729 4 Sensors....................................................................................................................................................................................................2731 4.1 Overview - Front Axle Speed Sensor...................................................................................................................................................................2731 4.2 Overview - Rear Axle Speed Sensor....................................................................................................................................................................2732 4.2.1 Overview - Rear Axle Speed Sensor, FWD.........................................................................................................................................................2732 4.2.2 Overview - Rear Axle Speed Sensor..............................................................................................................................................................2733 4.3 ESP Sensor Unit -G419-, Removing and Installing......................................................................................................................................................2733 4.4 Right/Left Front ABS Wheel Speed Sensor -G45-/-G47-, Removing and Installing.........................................................................................................................2734 4.5 Right/Left Rear ABS Wheel Speed Sensor -G44-/-G46-, Removing and Installing..........................................................................................................................2734 4.5.1 Right/Left Rear ABS Wheel Speed Sensor -G44-/-G46-, Removing and Installing, FWD...............................................................................................................2734 4.5.2 Right/Left Rear ABS Wheel Speed Sensor -G44-/-G46-, Removing and Installing, AWD...............................................................................................................2735 4.6 ABS Sensor Ring, Checking............................................................................................................................................................................2736 5 Special Tools..............................................................................................................................................................................................2737 46 – Mechanical Components.......................................................................................................................................................................................2739 1 Front Brakes...............................................................................................................................................................................................2739 1.1 Overview - Front Brakes..............................................................................................................................................................................2739 1.1.1 Overview - Front Brakes FS III.................................................................................................................................................................2739 1.1.2 Overview - Front Brakes PC57 and C60...........................................................................................................................................................2741 1.2 Brake Pads, Removing and Installing..................................................................................................................................................................2743 1.2.1 Brake Pads, Removing and Installing, Front Brakes FS III.......................................................................................................................................2743 1.2.2 Brake Pads, Removing and Installing, Front Brakes PC57 and C60.................................................................................................................................2745 1.3 Brake Caliper, Removing and Installing...............................................................................................................................................................2747 1.3.1 Brake Caliper, Removing and Installing, Front Brakes FS III....................................................................................................................................2747 1.3.2 Brake Caliper, Removing and Installing, Front Brakes PC57 and C60..............................................................................................................................2749 2 Rear Brakes................................................................................................................................................................................................2751 2.1 Overview - Rear Brakes...............................................................................................................................................................................2751 2.2 Brake Pads, Removing and Installing..................................................................................................................................................................2753 2.3 Brake Caliper, Removing and Installing...............................................................................................................................................................2757 3 Parking Brake..............................................................................................................................................................................................2761 3.1 Overview - Parking Brake Component Location..........................................................................................................................................................2761 3.2 Electromechanical Parking Brake Control Module -J540-, Removing and Installing.......................................................................................................................2762 3.3 Left/Right Parking Brake Motor -V282-/-V283-, Removing and Installing................................................................................................................................2762 4 Brake Pedal................................................................................................................................................................................................2765 4.1 Overview - Brake Pedal...............................................................................................................................................................................2765 4.1.1 Brake Pedal, Assembly Overview.................................................................................................................................................................2765 4.1.2 Overview - Brake Pedal, RHD....................................................................................................................................................................2767 4.2 Bracket, Removing and Installing.....................................................................................................................................................................2768 4.2.1 Mounting Bracket, Removing and Installing......................................................................................................................................................2768 4.2.2 Mounting Bracket, Removing and Installing, RHD.................................................................................................................................................2770 4.3 Brake Pedal, Removing from Brake Booster.............................................................................................................................................................2772 4.4 Brake Pedal, Attaching to Brake Booster..............................................................................................................................................................2773 4.5 Brake Pedal, Removing and Installing.................................................................................................................................................................2773 4.5.1 Brake Pedal, Removing and Installing...........................................................................................................................................................2773 5 Special Tools..............................................................................................................................................................................................2775 47 – Hydraulic Components........................................................................................................................................................................................2776 1 Front Brake Caliper........................................................................................................................................................................................2776 1.1 Overview - Front Brake Caliper.......................................................................................................................................................................2776 1.1.1 Overview - Brake Caliper FS III................................................................................................................................................................2776 1.1.2 Overview - Brake Caliper PC57..................................................................................................................................................................2777 1.2 Brake Caliper Piston, Removing and Installing........................................................................................................................................................2778 1.2.1 Brake Caliper Piston PC57, Removing and Installing.............................................................................................................................................2778 2 Rear Brake Caliper.........................................................................................................................................................................................2780 2.1 Overview - Rear Brake Caliper........................................................................................................................................................................2780 2.2 Dust Cap, Removing and Installing....................................................................................................................................................................2780 3 Brake Booster/Master Brake Cylinder........................................................................................................................................................................2783 3.1 Overview - Brake Booster/Master Brake Cylinder.......................................................................................................................................................2783 3.1.1 Overview - Brake Booster/Brake Master Cylinder.................................................................................................................................................2783 3.1.2 Overview - Brake Booster/Brake Master Cylinder, RHD............................................................................................................................................2785 3.2 Brake Lamp Switch, Removing and Installing...........................................................................................................................................................2787 3.2.1 Brake Lamp Switch, Removing and Installing.....................................................................................................................................................2787 3.2.2 Brake Lamp Switch, Removing and Installing, RHD Vehicle........................................................................................................................................2788 3.3 Brake Booster, Removing and Installing...............................................................................................................................................................2790 3.3.1 Brake Booster, Removing and Installing.........................................................................................................................................................2790 3.3.2 Brake Booster, Removing and Installing, RHD with Diesel Engine.................................................................................................................................2795 3.3.3 Brake Booster, Removing and Installing, RHD vehicles with 1.2L and 1.4L Gasoline Engines.......................................................................................................2804 3.4 Brake Master Cylinder, Removing and Installing.......................................................................................................................................................2812 3.4.1 Brake Master Cylinder, Removing and Installing.................................................................................................................................................2812 3.4.2 Brake Master Cylinder, Removing and Installing, RHD Vehicles...................................................................................................................................2815 4 Vacuum System..............................................................................................................................................................................................2821 4.1 Overview - Vacuum Pump...............................................................................................................................................................................2821 4.1.1 Brake Booster Vacuum Pump, Diesel Vehicles.....................................................................................................................................................2821 4.2 Check Valve, Checking................................................................................................................................................................................2821 4.3 Vacuum Sensor -G608-, Removing and Installing........................................................................................................................................................2821 4.4 Vacuum System, Checking..............................................................................................................................................................................2822 4.4.1 Test Instructions..............................................................................................................................................................................2822 4.4.2 Brake Servo Tester -VAS6721-, Connecting.......................................................................................................................................................2823 4.4.3 Vacuum, Checking...............................................................................................................................................................................2824 4.4.4 Leak Test......................................................................................................................................................................................2824 4.4.5 Vacuum, Creating with Hand Vacuum Pump -VAS6213-...............................................................................................................................................2826 5 Brake Lines................................................................................................................................................................................................2827 5.1 Brake Lines, Repairing...............................................................................................................................................................................2827 5.1.1 Overview - Flanging Tool.......................................................................................................................................................................2827 5.1.2 Flanging Tool, Instructions....................................................................................................................................................................2828 6 Hydraulic System...........................................................................................................................................................................................2831 6.1 Brake Fluid General Information......................................................................................................................................................................2831 6.1.1 Brake Fluid General Information................................................................................................................................................................2831 6.1.2 Brake Fluid, Changing..........................................................................................................................................................................2831 6.2 Hydraulic System, Standard Bleeding..................................................................................................................................................................2831 6.3 Hydraulic System, Post-Bleeding......................................................................................................................................................................2832 6.4 Checking for Leaks...................................................................................................................................................................................2832 7 Special Tools..............................................................................................................................................................................................2834 8 Revision History...........................................................................................................................................................................................2837 07-HVAC System.pdf (p.2838-3157).....................................................................................................................................................................................2838 00 – General, Technical Data.....................................................................................................................................................................................2844 1 Safety Precautions.........................................................................................................................................................................................2844 1.1 Handling Refrigerant Safety Precautions..............................................................................................................................................................2844 1.2 Start/Stop System Safety Precautions.................................................................................................................................................................2844 1.3 High Voltage System Safety Precautions...............................................................................................................................................................2844 1.4 Safety Precautions near High Voltage Components......................................................................................................................................................2845 1.5 Cooling System Safety Precautions....................................................................................................................................................................2845 1.6 Parking/Auxiliary Heater Safety Precautions..........................................................................................................................................................2845 2 Identification.............................................................................................................................................................................................2847 2.1 Heater and A/C Unit Identification...................................................................................................................................................................2847 2.1.1 Heater and A/C Unit Identification, Valeo......................................................................................................................................................2847 2.1.2 Heater and A/C Unit Identification, Denso......................................................................................................................................................2847 3 General Information........................................................................................................................................................................................2849 3.1 Odors in Vehicles with A/C System....................................................................................................................................................................2849 3.2 Vehicles with Start/Stop System General Information..................................................................................................................................................2849 3.3 Type Label...........................................................................................................................................................................................2850 4 Repair Information.........................................................................................................................................................................................2851 4.1 Working on the Refrigerant Circuit...................................................................................................................................................................2851 4.2 Refrigerant Circuit Seals............................................................................................................................................................................2851 4.3 Heating Output, Checking.............................................................................................................................................................................2852 4.3.1 Information on Checking Heat Output and Tools Required.........................................................................................................................................2852 4.3.2 Heating Output and Temperature Door Actuation, Checking, Vehicles without A/C System...........................................................................................................2854 4.3.3 Heating Output and Temperature Door Actuation, Checking, Vehicles with Manual Climate Control System...........................................................................................2857 4.3.4 Heating Output and Temperature Door Actuation, Checking, Vehicles with Automatic Climate Control System (Without High Voltage System)..........................................................2861 4.3.5 Heating Output and Temperature Door Actuation, Checking, Vehicles with High Voltage System and Automatic Climate Control System................................................................2866 4.4 Cooling Output, Checking.............................................................................................................................................................................2874 4.4.1 Information on Checking Cooling Output and Tools Required......................................................................................................................................2874 4.4.2 Test Requirements..............................................................................................................................................................................2875 4.4.3 Cooling Output, Checking, Vehicles with Manual Climate Control System..........................................................................................................................2879 4.4.4 Cooling Output, Checking, Vehicles with Automatic Climate Control System (without High Voltage System).........................................................................................2884 4.4.5 Cooling Output, Checking, Vehicles with Automatic Climate Control System (with High Voltage System)............................................................................................2889 4.4.6 Determining Malfunction if Deviation from Specified Value......................................................................................................................................2900 4.4.7 Determining Malfunction of Temperature Increase Downstream from Evaporator.....................................................................................................................2901 4.4.8 Ice Formation on Evaporator, Localizing Malfunction............................................................................................................................................2902 5 Technical Data.............................................................................................................................................................................................2905 5.1 Refrigerant R134a Capacities.........................................................................................................................................................................2905 5.2 Refrigerant Oil......................................................................................................................................................................................2905 5.3 Oil Distribution.....................................................................................................................................................................................2905 80 – Heating, Ventilation........................................................................................................................................................................................2906 1 Component Location Overview - Heating......................................................................................................................................................................2906 1.1 Component Location Overview - Components Outside of Passenger Compartment............................................................................................................................2906 1.1.1 Component Location Overview - Components Outside of Passenger Compartment......................................................................................................................2906 1.1.2 Component Location Overview - Components Outside of Passenger Compartment, Golf RHD............................................................................................................2907 1.1.3 Component Location Overview - Components Outside of Passenger Compartment, Wagon...............................................................................................................2908 1.1.4 Component Location Overview - Components Outside of Passenger Compartment, Golf Wagon RHD......................................................................................................2909 1.2 Component Location Overview - Components Inside Front Passenger Compartment..........................................................................................................................2910 1.2.1 Component Location Overview - Components Inside Front Passenger Compartment....................................................................................................................2910 1.2.2 Component Location Overview - Components Inside Front Passenger Compartment, RHD...............................................................................................................2911 2 Actuators..................................................................................................................................................................................................2913 2.1 Component Location Overview - Front Actuators........................................................................................................................................................2913 2.1.1 Component Location Overview - Front Actuators..................................................................................................................................................2913 2.1.2 Component Location Overview - Front Actuators, RHD.............................................................................................................................................2914 2.2 Temperature Regulator Door Motor -V68- with Temperature Regulator Door Motor Position Sensor -G92-, Removing and Installing..........................................................................2915 2.2.1 Temperature Regulator Door Motor -V68- with Temperature Regulator Door Motor Position Sensor -G92-, Removing and Installing....................................................................2915 2.2.2 Temperature Regulator Door Motor -V68- with Temperature Regulator Door Motor Position Sensor -G92-, Removing and Installing, RHD...............................................................2915 2.3 Recirculation Door Motor -V113-, Removing and Installing.............................................................................................................................................2915 2.3.1 Recirculation Door Motor -V113-, Removing and Installing.......................................................................................................................................2915 2.3.2 Recirculation Door Motor -V113-, Removing and Installing, RHD..................................................................................................................................2915 2.4 Air Distribution Door Motor -V428- with Position Sensor Air Distribution Door Motor Position Sensor -G645-, Removing and Installing..................................................................2916 2.4.1 Air Distribution Door Motor -V428- with Position Sensor Air Distribution Door Motor Position Sensor -G645-, Removing and Installing............................................................2916 2.4.2 Air Distribution Door Motor -V428- with Position Sensor Air Distribution Door Motor Position Sensor -G645-, Removing and Installing, RHD.......................................................2916 3 Heater.....................................................................................................................................................................................................2917 3.1 Overview - Heater....................................................................................................................................................................................2917 3.2 Fresh Air Blower -V2-, Removing and Installing.......................................................................................................................................................2922 3.3 Fresh Air Blower Control Module -J126-, Removing and Installing......................................................................................................................................2922 3.4 Dust and Pollen Filter, Removing and Installing......................................................................................................................................................2922 3.5 Heater, Removing and Installing......................................................................................................................................................................2922 3.6 Heater, Disassembling and Assembling.................................................................................................................................................................2922 3.7 Auxiliary Heater Heating Element -Z35- with Auxiliary Air Heater Control Module -J604-, Checking.....................................................................................................2922 3.8 Auxiliary Heater Heating Element - Z35- with Auxiliary Air Heater Control Module -J604-, Removing and Installing.....................................................................................2923 3.9 Heater Core, Removing and Installing.................................................................................................................................................................2923 3.10 Partition, Removing and Installing..................................................................................................................................................................2923 4 Air Routing................................................................................................................................................................................................2924 4.1 Overview - Air Routing and Air Distribution in Passenger Compartment.................................................................................................................................2924 4.2 Driver Side Footwell Vent, Removing and Installing...................................................................................................................................................2924 4.3 Front Passenger Side Footwell Vent, Removing and Installing..........................................................................................................................................2924 4.4 Rear Footwell Vent, Removing and Installing..........................................................................................................................................................2924 4.5 Fresh Air Intake, Removing and Installing............................................................................................................................................................2925 4.6 Fresh Air Intake Cover, Removing and Installing......................................................................................................................................................2925 4.7 Air Intake Duct, Removing and Installing.............................................................................................................................................................2925 4.8 Passenger Compartment Forced Air Extraction, Checking................................................................................................................................................2925 4.9 Passenger Compartment Forced Air Extraction, Removing and Installing.................................................................................................................................2925 4.10 Air Guide for Defrost Air Vent, Removing and Installing.............................................................................................................................................2925 4.11 Center Instrument Panel Vent Air Guide, Removing and Installing.....................................................................................................................................2925 5 Display and Control Head...................................................................................................................................................................................2926 5.1 Overview - Display and Control Head..................................................................................................................................................................2926 5.2 Display and Control Head, Removing and Installing....................................................................................................................................................2927 6 Additional Components for Control and Regulation...........................................................................................................................................................2928 6.1 Outside Air Temperature Sensor -G17-, Removing and Installing........................................................................................................................................2928 87 – Air Conditioning............................................................................................................................................................................................2929 1 Component Location Overview - A/C System...................................................................................................................................................................2929 1.1 Component Location Overview - Components Outside of Passenger Compartment............................................................................................................................2929 1.1.1 Component Location Overview - Components Outside of Passenger Compartment, Golf and Golf GTE...................................................................................................2929 1.1.2 Component Location Overview - Components Outside of Passenger Compartment, Golf and Golf GTE, RHD..............................................................................................2931 1.1.3 Component Location Overview - Components Outside of Passenger Compartment, Golf Wagon..........................................................................................................2933 1.1.4 Component Location Overview - Components Outside of Passenger Compartment, Golf Wagon RHD......................................................................................................2935 1.2 Component Location Overview - Components Inside Front Passenger Compartment..........................................................................................................................2937 1.2.1 Component Location Overview - Components Inside Front Passenger Compartment....................................................................................................................2937 1.2.2 Component Location Overview - Components Inside Front Passenger Compartment, RHD...............................................................................................................2940 2 Refrigerant Circuit........................................................................................................................................................................................2943 2.1 System Overview - Refrigerant Circuit................................................................................................................................................................2943 2.1.1 System Overview - Refrigerant Circuit..........................................................................................................................................................2943 2.1.2 System Overview - Refrigerant Circuit, Golf GTE................................................................................................................................................2946 2.2 Overview - Condenser.................................................................................................................................................................................2951 2.3 Refrigerant Circuit Pressure Sensor -G805-, Removing and Installing..................................................................................................................................2952 2.4 Expansion Valve, Removing and Installing.............................................................................................................................................................2953 2.4.1 Expansion Valve, Removing and Installing, Golf and Golf Wagon..................................................................................................................................2953 2.4.2 Expansion Valve, Removing and Installing, Golf GTE.............................................................................................................................................2956 2.5 Condenser, Removing and Installing...................................................................................................................................................................2959 2.6 Dryer Bag/Dryer Cartridge, Removing and Installing...................................................................................................................................................2961 2.6.1 Dryer Bag, Removing and Installing, Denso Condenser............................................................................................................................................2961 2.6.2 Dryer Bag, Removing and Installing, Modine Condenser...........................................................................................................................................2963 2.6.3 Dryer Bag, Removing and Installing, Keihin Condenser...........................................................................................................................................2966 2.7 Low Pressure Side Refrigerant Line Balance Weight, Removing and Installing...........................................................................................................................2969 2.8 Evacuating and Charging Valve, Removing and Installing, Low and High Pressure Side...................................................................................................................2970 2.9 A/C Pressure/Temperature Sensor -G395-, Removing and Installing......................................................................................................................................2971 2.10 Heater and A/C Unit Refrigerant Cut-Off Valve -N541-, Removing and Installing.......................................................................................................................2972 2.11 High Voltage Battery Heater Core Refrigerant Cut-Off Valve -N542-, Removing and Installing..........................................................................................................2974 2.12 High Voltage Battery Heat Exchanger, Removing and Installing........................................................................................................................................2976 2.13 Refrigerant Lines with Inner Heat Exchanger, Removing and Installing................................................................................................................................2979 2.13.1 Refrigerant Lines with Inner Heat Exchanger, Removing and Installing, Golf and Golf Wagon.....................................................................................................2979 2.13.2 Refrigerant Lines with Inner Heat Exchanger, Removing and Installing, Golf GTE................................................................................................................2982 2.14 Refrigerant Line with Restrictor....................................................................................................................................................................2984 2.15 Condenser/Evaporator Refrigerant Line, Removing and Installing......................................................................................................................................2985 2.16 Condenser/A/C Compressor Refrigerant Line, Removing and Installing..................................................................................................................................2987 2.17 A/C Compressor/Evaporator Refrigerant Line, Removing and Installing.................................................................................................................................2989 3 A/C Compressor.............................................................................................................................................................................................2992 3.1 Overview - A/C Compressor Power Unit.................................................................................................................................................................2992 3.1.1 Overview - A/C Compressor Power Unit, Golf and Golf Wagon......................................................................................................................................2992 3.1.2 Overview - A/C Compressor Power Unit, Golf GTE.................................................................................................................................................2994 3.2 Overview - Belt Pulley...............................................................................................................................................................................2996 3.2.1 Overview - Belt Pulley, Denso A/C Compressor...................................................................................................................................................2996 3.2.2 Overview - Belt Pulley, Sanden A/C Compressor..................................................................................................................................................2997 3.3 A/C Compressor, Removing and Installing on Bracket...................................................................................................................................................2998 3.3.1 A/C Compressor, Removing and Installing on Bracket, Golf and Golf Wagon........................................................................................................................2998 3.3.2 A/C Compressor, Removing and Installing on Bracket, Golf GTE...................................................................................................................................3000 3.4 A/C Compressor, Removing and Installing..............................................................................................................................................................3002 3.4.1 A/C Compressor, Removing and Installing, Golf and Golf Wagon...................................................................................................................................3002 3.4.2 Electrical A/C Compressor -V470-, Removing and Installing, Golf GTE............................................................................................................................3006 3.5 A/C Compressor Fuse -S355-, Removing and Installing..................................................................................................................................................3008 3.6 Pressure Relieve Valve on A/C Compressor, Checking...................................................................................................................................................3010 3.7 Belt Pulley, Removing and Installing.................................................................................................................................................................3011 3.7.1 Belt Pulley, Removing and Installing, Denso....................................................................................................................................................3011 3.7.2 Belt Pulley, Removing and Installing, Sanden...................................................................................................................................................3013 4 Actuators..................................................................................................................................................................................................3014 4.1 Component Location Overview - Front Actuators........................................................................................................................................................3014 4.1.1 Component Location Overview - Front Actuators, Electric-Manual Climate Control System..........................................................................................................3014 4.1.2 Component Location Overview - Front Actuators, Electric-Manual Climate Control System, RHD.....................................................................................................3016 4.1.3 Component Location Overview - Front Actuators, Climatronic.....................................................................................................................................3016 4.1.4 Component Location Overview - Front Actuators, Climatronic, RHD................................................................................................................................3018 4.2 Temperature Regulator Door Motor -V68- with Temperature Regulator Door Motor Position Sensor -G92-, Removing and Installing..........................................................................3019 4.2.1 Temperature Regulator Door Motor -V68-, Removing and Installing................................................................................................................................3019 4.2.2 Temperature Regulator Door Motor -V68-, Removing and Installing, RHD...........................................................................................................................3020 4.3 Defroster Door Motor -V107- with Defroster Door Motor Position Sensor -G135-, Removing and Installing................................................................................................3022 4.3.1 Defroster Door Motor -V107- with Defroster Door Motor Position Sensor -G135-, Removing and Installing..........................................................................................3022 4.3.2 Defroster Door Motor -V107- with Defroster Door Motor Position Sensor -G135-, Removing and Installing, RHD.....................................................................................3024 4.4 Recirculation Door Motor -V113-, Removing and Installing.............................................................................................................................................3026 4.4.1 Recirculation Door Motor -V113-, Removing and Installing.......................................................................................................................................3026 4.4.2 Recirculation Door Motor -V113-, Removing and Installing, RHD..................................................................................................................................3027 4.5 Left Temperature Door Motor -V158- with Left Temperature Door Potentiometer/Actuator -G220-, Removing and Installing.................................................................................3030 4.5.1 Left Temperature Door Motor -V158-, Removing and Installing....................................................................................................................................3030 4.5.2 Left Temperature Door Motor -V158-, Removing and Installing, RHD...............................................................................................................................3031 4.6 Right Temperature Door Motor -V159- with Right Temperature Door Potentiometer/Actuator -G221-, Removing and Installing...............................................................................3033 4.6.1 Right Temperature Door Motor -V159-, Removing and Installing...................................................................................................................................3033 4.6.2 Right Temperature Door Motor -V159-, Removing and Installing, RHD..............................................................................................................................3035 4.7 Fresh Air/Recirculating Air/Back Pressure Door Motor -V425- with Fresh Air/Recirculating Air/Back Pressure Door Motor Position Sensor -G644-, Removing and Installing................................3038 4.7.1 Fresh Air/Recirculating Air/Back Pressure Door Motor -V425-, Removing and Installing...........................................................................................................3038 4.7.2 Fresh Air/Recirculating Air/Back Pressure Door Motor -V425-, Removing and Installing, RHD......................................................................................................3039 4.8 Front Air Distribution Door Motor -V426- with Air Distribution Door Motor Position Sensor -G642-, Removing and Installing............................................................................3042 4.8.1 Air Distribution Door Motor -V426-, Removing and Installing....................................................................................................................................3042 4.8.2 Air Distribution Door Motor -V426-, Removing and Installing, RHD...............................................................................................................................3044 4.9 Air Distribution Door Motor -V428- with Position Sensor Air Distribution Door Motor Position Sensor -G645-, Removing and Installing..................................................................3045 4.9.1 Air Distribution Door Motor - V428-, Removing and Installing...................................................................................................................................3045 4.9.2 Air Distribution Door Motor - V428-, Removing and Installing, RHD..............................................................................................................................3047 4.10 Air Distribution Door Adjuster, Removing and Installing.............................................................................................................................................3050 4.10.1 Front Air Distribution Door Adjuster, Removing and Installing, Heater and Electric-Manual Climate Control System..............................................................................3050 4.10.2 Front Air Distribution Door Adjuster, Removing and Installing, Heater and Electric-Manual Climate Control System, RHD.........................................................................3051 4.10.3 Front Air Distribution Door Adjuster, Removing and Installing, Climatronic....................................................................................................................3052 4.10.4 Front Air Distribution Door Adjuster, Removing and Installing, Climatronic, RHD...............................................................................................................3053 5 Front Heater and A/C Unit..................................................................................................................................................................................3056 5.1 Overview - Heater and A/C Unit.......................................................................................................................................................................3056 5.1.1 Overview - Heater and A/C Unit, Climatronic....................................................................................................................................................3056 5.2 Overview - Attachments for Heater and A/C Unit and Air Intake Housing................................................................................................................................3061 5.3 Overview - Evaporator Housing........................................................................................................................................................................3063 5.4 Overview - Air Distribution Housing Doors and Partitions.............................................................................................................................................3065 5.5 Heater and A/C Unit, Removing and Installing.........................................................................................................................................................3067 5.6 Heater and A/C Unit, Disassembling and Assembling....................................................................................................................................................3071 5.7 Air Distribution Housing, Removing and Installing....................................................................................................................................................3073 5.8 Heater and A/C Unit Bracket, Removing and Installing.................................................................................................................................................3073 5.9 Evaporator, Removing and Installing..................................................................................................................................................................3074 5.10 Fresh Air Blower Control Module -J126-, Removing and Installing.....................................................................................................................................3076 5.10.1 Fresh Air Blower Control Module -J126-, Removing and Installing...............................................................................................................................3076 5.10.2 Fresh Air Blower Control Module -J126-, Removing and Installing, RHD..........................................................................................................................3076 5.11 Dust and Pollen Filter, Removing and Installing.....................................................................................................................................................3077 5.11.1 Dust and Pollen Filter, Removing and Installing...............................................................................................................................................3077 5.11.2 Dust and Pollen Filter, Removing and Installing, RHD..........................................................................................................................................3079 5.12 Fresh Air Blower -V2-, Removing and Installing......................................................................................................................................................3081 5.12.1 Fresh Air Blower -V2-, Removing and Installing................................................................................................................................................3081 5.12.2 Fresh Air Blower -V2-, Removing and Installing, RHD...........................................................................................................................................3082 5.13 Auxiliary Heater Heating Element -Z35- with Auxiliary Air Heater Control Module -J604-, Checking....................................................................................................3083 5.13.1 Auxiliary Heater Heating Element -Z35- with Auxiliary Air Heater Control Module -J604-, Checking..............................................................................................3083 5.13.2 Auxiliary Heater Heating Element -Z35- with Auxiliary Air Heater Control Module -J604-, Checking, RHD.........................................................................................3084 5.14 Auxiliary Heater Heating Element - Z35- with Auxiliary Air Heater Control Module -J604-, Removing and Installing....................................................................................3085 5.14.1 Auxiliary Heater Heating Element - Z35- with Auxiliary Air Heater Control Module -J604-, Removing and Installing..............................................................................3085 5.14.2 Auxiliary Heater Heating Element - Z35- with Auxiliary Air Heater Control Module -J604-, Removing and Installing, RHD.........................................................................3086 5.15 Heater Core, Removing and Installing................................................................................................................................................................3087 5.15.1 Heater Core, Removing and Installing, Valeo...................................................................................................................................................3087 5.15.2 Heater Core, Removing and Installing, Valeo, RHD..............................................................................................................................................3091 5.15.3 Heater Core, Removing and Installing, Denso...................................................................................................................................................3095 5.15.4 Heater Core, Removing and Installing, Denso, RHD..............................................................................................................................................3098 5.16 Heater Core Coolant Pipes, Removing and Installing..................................................................................................................................................3103 5.16.1 Heater Core Coolant Pipes, Removing and Installing, Valeo.....................................................................................................................................3103 5.16.2 Heater Core Coolant Pipes, Removing and Installing, Denso.....................................................................................................................................3104 5.17 Evaporator Temperature Sensor -G308-, Removing and Installing.......................................................................................................................................3105 5.17.1 Evaporator Temperature Sensor -G308-, Removing and Installing.................................................................................................................................3105 5.17.2 Evaporator Temperature Sensor -G308-, Removing and Installing, RHD............................................................................................................................3106 5.18 Condensation Water Drain, Checking..................................................................................................................................................................3107 5.19 Condensation Water Drain, Removing and Installing...................................................................................................................................................3108 5.19.1 Condensation Water Drain, Removing and Installing.............................................................................................................................................3108 5.19.2 Condensation Water Drain, Removing and Installing, RHD........................................................................................................................................3110 5.20 Partition, Removing and Installing..................................................................................................................................................................3112 5.20.1 Partition, Removing and Installing............................................................................................................................................................3112 5.20.2 Partition, Removing and Installing, RHD.......................................................................................................................................................3113 6 Air Routing................................................................................................................................................................................................3114 6.1 Overview - Air Routing and Air Distribution in Passenger Compartment.................................................................................................................................3114 6.2 Fresh Air Intake, Removing and Installing............................................................................................................................................................3116 6.2.1 Fresh Air Intake, Removing and Installing......................................................................................................................................................3116 6.2.2 Fresh Air Intake, Removing and Installing, RHD.................................................................................................................................................3116 6.3 Fresh Air Intake Cover, Removing and Installing......................................................................................................................................................3117 6.3.1 Fresh Air Intake Cover, Removing and Installing................................................................................................................................................3117 6.3.2 Fresh Air Intake Cover, Removing and Installing, RHD...........................................................................................................................................3118 6.4 Air Intake Duct, Removing and Installing.............................................................................................................................................................3119 6.5 Driver Side Footwell Vent, Removing and Installing...................................................................................................................................................3119 6.5.1 Driver Side Footwell Vent, Removing and Installing.............................................................................................................................................3119 6.5.2 Driver Side Footwell Vent, Removing and Installing, RHD........................................................................................................................................3120 6.6 Front Passenger Side Footwell Vent, Removing and Installing..........................................................................................................................................3120 6.6.1 Front Passenger Side Footwell Vent, Removing and Installing....................................................................................................................................3120 6.6.2 Front Passenger Side Footwell Vent, Removing and Installing, RHD...............................................................................................................................3121 6.7 Rear Footwell Vent, Removing and Installing..........................................................................................................................................................3122 6.8 Rear Center Console Vent Air Guide Channel, Removing and Installing..................................................................................................................................3122 6.9 Passenger Compartment Forced Air Extraction, Checking................................................................................................................................................3123 6.10 Passenger Compartment Forced Air Extraction, Removing and Installing................................................................................................................................3124 6.10.1 Passenger Compartment Forced Air Extraction, Removing and Installing, Golf....................................................................................................................3124 6.10.2 Passenger Compartment Forced Air Extraction, Removing and Installing, Golf Wagon..............................................................................................................3124 6.11 Air Guide for Defrost Air Vent, Removing and Installing.............................................................................................................................................3125 6.12 Center Instrument Panel Vent Air Guide, Removing and Installing.....................................................................................................................................3125 7 Coolant Circuit............................................................................................................................................................................................3126 7.1 High Voltage Heater (PTC) -Z115-, Incorporation in Coolant Circuit...................................................................................................................................3126 7.2 High Voltage Battery Heat Exchanger Incorporation in the High Voltage System Coolant Circuit.........................................................................................................3131 7.3 High Voltage Battery Coolant Valve -N688-, Removing and Installing...................................................................................................................................3133 7.4 High Voltage Battery Coolant Pump -V590-, Removing and Installing....................................................................................................................................3134 7.5 High Voltage Heater (PTC) -Z115-/High Voltage Heater (PTC) Control Module -J848-, Removing and Installing............................................................................................3135 8 Display and Control Head...................................................................................................................................................................................3140 8.1 Component Location Overview - Display and Control Head...............................................................................................................................................3140 8.1.1 Component Location Overview - Display and Control Head, Electric-Manual Climate Control System.................................................................................................3140 8.1.2 Component Location Overview - Display and Control Head, Climatronic............................................................................................................................3142 8.2 Display and Control Head, Removing and Installing....................................................................................................................................................3144 8.2.1 Display and Control Head, Removing and Installing, Electric-Manual Climate Control System and Climatronic......................................................................................3144 9 Additional Components for Control and Regulation...........................................................................................................................................................3146 9.1 Sunlight Photo Sensor -G107-, Removing and Installing................................................................................................................................................3146 9.2 Air Quality Sensor -G238-, Removing and Installing...................................................................................................................................................3147 9.2.1 Air Quality Sensor -G238-, Removing and Installing.............................................................................................................................................3147 9.2.2 Air Quality Sensor -G238-, Removing and Installing, RHD........................................................................................................................................3148 9.3 Function of Air Quality Sensor -G238-................................................................................................................................................................3148 9.4 Outside Air Temperature Sensor -G17-, Removing and Installing........................................................................................................................................3150 9.5 A/C Humidity Sensor -G260-, Removing and Installing..................................................................................................................................................3150 9.6 Left Vent Temperature Sensor -G150-, Removing and Installing.........................................................................................................................................3150 9.7 Right Vent Temperature Sensor -G151-, Removing and Installing........................................................................................................................................3151 9.8 Footwell Vent Temperature Sensor -G192-, Removing and Installing.....................................................................................................................................3152 10 Special Tools.............................................................................................................................................................................................3154 11 Revision History..........................................................................................................................................................................................3157 08-Body.pdf (p.3158-4818)............................................................................................................................................................................................3158 08-01 Body Repairs...............................................................................................................................................................................................3158 00 – General, Technical Data.................................................................................................................................................................................3164 1 General Information...................................................................................................................................................................................3164 2 Vehicle Data...........................................................................................................................................................................................3165 2.1 Vehicle Identification Number....................................................................................................................................................................3165 2.2 Type Plate.......................................................................................................................................................................................3166 2.3 Vehicle Data Label...............................................................................................................................................................................3166 3 Safety Precautions.....................................................................................................................................................................................3167 4 Molded Foam Parts......................................................................................................................................................................................3168 5 Galvanized Body Parts and High-Strength/Highest Strength Hot Formed Body Panels........................................................................................................................3170 5.1 Assembly.........................................................................................................................................................................................3170 5.2 2-Door Vehicle...................................................................................................................................................................................3172 5.3 4-Door Vehicle...................................................................................................................................................................................3174 6 Laser Welds............................................................................................................................................................................................3176 7 Gap Dimensions.........................................................................................................................................................................................3177 7.1 Body Front.......................................................................................................................................................................................3177 7.2 Body, Center.....................................................................................................................................................................................3178 7.3 Body, Rear.......................................................................................................................................................................................3181 8 Body Panel Dimensions..................................................................................................................................................................................3182 8.1 Body Front.......................................................................................................................................................................................3182 8.2 Body, Center.....................................................................................................................................................................................3183 8.2.1 2-Door Vehicle.............................................................................................................................................................................3184 8.2.2 4-Door Vehicle.............................................................................................................................................................................3187 8.3 Body, Rear.......................................................................................................................................................................................3190 8.4 Front Floor Assembly.............................................................................................................................................................................3191 8.5 Center Floor Assembly............................................................................................................................................................................3192 8.6 Rear Floor Assembly..............................................................................................................................................................................3193 9 Alignment Bracket Set..................................................................................................................................................................................3194 9.1 Overview.........................................................................................................................................................................................3194 10 Portal Gauge..........................................................................................................................................................................................3195 50 – Body Front..............................................................................................................................................................................................3196 1 Subframe Mounting Bracket, Removing and Installing.....................................................................................................................................................3196 1.1 Tools............................................................................................................................................................................................3197 1.2 Removing.........................................................................................................................................................................................3197 1.3 Installing.......................................................................................................................................................................................3198 1.3.1 Preparing New Parts........................................................................................................................................................................3198 1.3.2 Welding....................................................................................................................................................................................3199 2 Front Bumper Bracket, Replacing........................................................................................................................................................................3200 2.1 Tools............................................................................................................................................................................................3201 2.2 Removing.........................................................................................................................................................................................3201 2.3 Installing.......................................................................................................................................................................................3202 2.3.1 Welding....................................................................................................................................................................................3202 3 Upper Wheel Housing Longitudinal Member, Replacing.....................................................................................................................................................3204 3.1 Tools............................................................................................................................................................................................3205 3.2 Removing.........................................................................................................................................................................................3205 3.3 Installing.......................................................................................................................................................................................3206 3.3.1 Preparing New Parts........................................................................................................................................................................3206 3.3.2 Welding....................................................................................................................................................................................3207 4 Front Wheel Housing, Replacing.........................................................................................................................................................................3209 4.1 Tools............................................................................................................................................................................................3210 4.2 Removing.........................................................................................................................................................................................3210 4.3 Installing.......................................................................................................................................................................................3211 4.3.1 Welding....................................................................................................................................................................................3211 5 Subframe Mount Thread, Servicing.......................................................................................................................................................................3213 5.1 Contents of Thread Repair Set....................................................................................................................................................................3215 5.2 Threads, Repairing...............................................................................................................................................................................3215 5.2.1 Threads, Drilling..........................................................................................................................................................................3215 5.2.2 Threads, Cutting...........................................................................................................................................................................3216 5.2.3 Thread Inserts, Inserting..................................................................................................................................................................3217 6 Front Longitudinal Member, Replacing...................................................................................................................................................................3219 6.1 Tools............................................................................................................................................................................................3220 6.2 Removing.........................................................................................................................................................................................3220 6.3 Installing.......................................................................................................................................................................................3221 6.3.1 Preparing New Parts........................................................................................................................................................................3221 6.3.2 Welding....................................................................................................................................................................................3222 7 Front Longitudinal Member, Replacing, Left Partial Section.............................................................................................................................................3225 7.1 Tools............................................................................................................................................................................................3226 7.2 Removing.........................................................................................................................................................................................3226 7.3 Installing.......................................................................................................................................................................................3227 7.3.1 Preparing New Parts........................................................................................................................................................................3227 7.3.2 Welding....................................................................................................................................................................................3228 8 Front Longitudinal Member, Replacing, Right Partial Section...........................................................................................................................................3230 8.1 Tools............................................................................................................................................................................................3231 8.2 Removing.........................................................................................................................................................................................3231 8.3 Installing.......................................................................................................................................................................................3232 8.3.1 New Part, Preparing........................................................................................................................................................................3232 8.3.2 Welding....................................................................................................................................................................................3233 9 Special Tools..........................................................................................................................................................................................3235 51 – Body Center, Chassis, Roof..............................................................................................................................................................................3236 1 Roof Replacing- Vehicles without a Panorama-Sunroof....................................................................................................................................................3236 1.1 Tools............................................................................................................................................................................................3237 1.2 Removing.........................................................................................................................................................................................3237 1.3 Installing.......................................................................................................................................................................................3239 1.3.1 Preparing New Parts........................................................................................................................................................................3239 1.3.2 Roof Depth Dimension, Adjusting............................................................................................................................................................3240 1.3.3 Roof, Bonding..............................................................................................................................................................................3241 1.3.4 Welding....................................................................................................................................................................................3247 2 Roof, Replacing, Vehicles with Panorama Sunroof........................................................................................................................................................3250 2.1 Tools............................................................................................................................................................................................3251 2.2 Removing.........................................................................................................................................................................................3251 2.3 Installing.......................................................................................................................................................................................3253 2.3.1 New Part, Preparing........................................................................................................................................................................3253 2.3.2 Roof Depth Dimension, Adjusting............................................................................................................................................................3255 2.3.3 Roof, Bonding..............................................................................................................................................................................3256 2.3.4 Welding....................................................................................................................................................................................3262 3 A-Pillar, Replacing....................................................................................................................................................................................3264 3.1 Tools............................................................................................................................................................................................3265 3.2 Removing.........................................................................................................................................................................................3265 3.3 Installing.......................................................................................................................................................................................3267 3.3.1 Preparing New Parts........................................................................................................................................................................3269 3.3.2 Welding....................................................................................................................................................................................3271 4 A-Pillar Reinforcement, Replacing Partial Section......................................................................................................................................................3273 4.1 Tools............................................................................................................................................................................................3274 4.2 Removing.........................................................................................................................................................................................3274 4.3 Installing.......................................................................................................................................................................................3275 4.3.1 Preparing New Parts........................................................................................................................................................................3275 4.3.2 Welding....................................................................................................................................................................................3276 5 B-Pillar, 4-Door Vehicle, Removing and Installing......................................................................................................................................................3279 5.1 Tools............................................................................................................................................................................................3280 5.2 Removing.........................................................................................................................................................................................3280 5.3 Installing.......................................................................................................................................................................................3281 5.3.1 Preparing New Parts........................................................................................................................................................................3281 5.3.2 Welding....................................................................................................................................................................................3283 6 B-Pillar Reinforcement, Replacing, 4-Door (Partial Section)............................................................................................................................................3285 6.1 Tools............................................................................................................................................................................................3286 6.2 Removing.........................................................................................................................................................................................3286 6.3 Installing.......................................................................................................................................................................................3289 6.3.1 New Part, Preparing........................................................................................................................................................................3289 6.3.2 Molded Foam Parts..........................................................................................................................................................................3291 6.3.3 Welding....................................................................................................................................................................................3292 7 Outer Sill Panel, Replacing, 4-Door...................................................................................................................................................................3298 7.1 Tools............................................................................................................................................................................................3299 7.2 Removing.........................................................................................................................................................................................3299 7.3 Installing.......................................................................................................................................................................................3300 7.3.1 Additional Separation Cuts on the Outer Sill Panel.........................................................................................................................................3300 7.3.2 Preparing New Parts........................................................................................................................................................................3301 7.3.3 Welding....................................................................................................................................................................................3303 8 Outer Sill Panel, Replacing, 2-Door...................................................................................................................................................................3305 8.1 Tools............................................................................................................................................................................................3306 8.2 Removing.........................................................................................................................................................................................3306 8.3 Installing.......................................................................................................................................................................................3307 8.3.1 Additional Separation Cuts on the Outer Sill Panel.........................................................................................................................................3307 8.3.2 Preparing New Parts........................................................................................................................................................................3308 8.3.3 Welding....................................................................................................................................................................................3310 9 Special Tools..........................................................................................................................................................................................3312 53 – Body Rear...............................................................................................................................................................................................3313 1 Rear Cross Panel, Replacing............................................................................................................................................................................3313 1.1 Tools............................................................................................................................................................................................3314 1.2 Removing.........................................................................................................................................................................................3315 1.3 Installing.......................................................................................................................................................................................3316 1.3.1 Preparing New Parts........................................................................................................................................................................3317 1.3.2 Welding....................................................................................................................................................................................3318 2 Corner Reinforcement, Replacing........................................................................................................................................................................3320 2.1 Tools............................................................................................................................................................................................3321 2.2 Removing.........................................................................................................................................................................................3321 2.3 Installing.......................................................................................................................................................................................3322 2.3.1 Preparing New Parts........................................................................................................................................................................3322 2.3.2 Welding....................................................................................................................................................................................3323 3 Tail Lamp Mount, Removing and Installing...............................................................................................................................................................3325 3.1 Tools............................................................................................................................................................................................3326 3.2 Removing.........................................................................................................................................................................................3326 3.3 Installing.......................................................................................................................................................................................3327 3.3.1 Preparing New Parts........................................................................................................................................................................3327 3.3.2 Welding....................................................................................................................................................................................3329 4 End Crossmember, Replacing.............................................................................................................................................................................3331 4.1 Tools............................................................................................................................................................................................3332 4.2 Removing.........................................................................................................................................................................................3332 4.3 Installing.......................................................................................................................................................................................3333 4.3.1 Preparing New Parts........................................................................................................................................................................3334 4.3.2 Welding....................................................................................................................................................................................3335 5 Luggage Compartment Floor, Replacing...................................................................................................................................................................3337 5.1 Tools............................................................................................................................................................................................3338 5.2 Removing.........................................................................................................................................................................................3339 5.3 Installing.......................................................................................................................................................................................3340 5.3.1 New Part, Preparing........................................................................................................................................................................3341 5.3.2 Molded Foam Parts..........................................................................................................................................................................3342 5.3.3 Welding....................................................................................................................................................................................3342 6 Luggage Compartment Floor, Replacing, with Hybrid Drive...............................................................................................................................................3344 6.1 Tools............................................................................................................................................................................................3345 6.2 Removing.........................................................................................................................................................................................3346 6.3 Installing.......................................................................................................................................................................................3347 6.3.1 New Part, Preparing........................................................................................................................................................................3347 6.3.2 Molded Foam Parts..........................................................................................................................................................................3348 6.3.3 Welding....................................................................................................................................................................................3349 7 Luggage Compartment Floor, Replacing, Hybrid Vehicles.................................................................................................................................................3351 7.1 Tools............................................................................................................................................................................................3352 7.2 Removing.........................................................................................................................................................................................3353 7.3 Installing.......................................................................................................................................................................................3354 7.3.1 Preparing New Parts........................................................................................................................................................................3355 7.3.2 Molded Foam Parts..........................................................................................................................................................................3355 7.3.3 Welding....................................................................................................................................................................................3356 8 Rear Longitudinal Member, Replacing, Partial Section...................................................................................................................................................3358 8.1 Tools............................................................................................................................................................................................3359 8.2 Removing.........................................................................................................................................................................................3359 8.3 Installing.......................................................................................................................................................................................3361 8.3.1 Preparing New Parts........................................................................................................................................................................3361 8.3.2 Welding....................................................................................................................................................................................3362 9 Side Panel, Replacing, 4-Door..........................................................................................................................................................................3364 9.1 Tools............................................................................................................................................................................................3365 9.2 Removing.........................................................................................................................................................................................3365 9.3 Installing.......................................................................................................................................................................................3368 9.3.1 Permitted Separating Cuts on Whole Side Panel..............................................................................................................................................3368 9.3.2 Preparing New Parts........................................................................................................................................................................3369 9.3.3 Molded Foam Parts..........................................................................................................................................................................3370 9.3.4 Welding....................................................................................................................................................................................3371 10 Side Panel, Replacing, 2-Door Vehicle.................................................................................................................................................................3374 10.1 Tools...........................................................................................................................................................................................3375 10.2 Removing........................................................................................................................................................................................3375 10.3 Installing......................................................................................................................................................................................3378 10.3.1 Permitted Separating Cuts on Whole Side Panel.............................................................................................................................................3378 10.3.2 Preparing New Parts.......................................................................................................................................................................3379 10.3.3 Molded Foam Parts.........................................................................................................................................................................3380 10.3.4 Welding...................................................................................................................................................................................3381 11 Outer Wheel Housing Liner, Replacing..................................................................................................................................................................3384 11.1 Tools...........................................................................................................................................................................................3385 11.2 Removing........................................................................................................................................................................................3386 11.3 Installing......................................................................................................................................................................................3388 11.3.1 Preparing New Parts.......................................................................................................................................................................3389 11.3.2 Welding...................................................................................................................................................................................3390 12 Special Tools.........................................................................................................................................................................................3394 13 Revision History......................................................................................................................................................................................3395 08-02 Body Repair Body Collision Repair..........................................................................................................................................................................3399 1 Safety Instructions........................................................................................................................................................................................3403 1.1 Removing Components..................................................................................................................................................................................3403 1.2 Battery, Welding Work................................................................................................................................................................................3403 1.3 Electronic Control Units.............................................................................................................................................................................3403 1.3.1 Procedure for Electronic Control Units after Accident Repairs..................................................................................................................................3403 1.4 Paint, Glass, Upholstery, Trim.......................................................................................................................................................................3404 1.5 Fuel Tank or Fuel Lines..............................................................................................................................................................................3404 1.6 Air Conditioner......................................................................................................................................................................................3404 1.6.1 Remedy.........................................................................................................................................................................................3404 1.7 Airbag System........................................................................................................................................................................................3405 1.8 Seat Belts, Checking.................................................................................................................................................................................3405 1.8.1 Belt Strap, Checking...........................................................................................................................................................................3405 1.8.2 Inertia Reel Locking Effect, Checking..........................................................................................................................................................3406 1.8.3 Belt Lock, Visual Check........................................................................................................................................................................3407 1.8.4 Belt Lock, Functional Check....................................................................................................................................................................3407 1.8.5 Belt Guides and Lock Tongues, Checking.........................................................................................................................................................3407 1.8.6 Securing Parts and Anchorage Points, Checking..................................................................................................................................................3408 1.9 Safety Regulations for Belt Tensioners...............................................................................................................................................................3408 1.10 Repairs on Vehicles with Belt Tensioners............................................................................................................................................................3408 1.10.1 Belt Tensioner Applications...................................................................................................................................................................3409 1.11 Cutting, Straightening and/or Bending Operations on Vehicles with Airbag............................................................................................................................3410 1.12 Front Seats with Side Airbag........................................................................................................................................................................3410 2 Basic Instructions.........................................................................................................................................................................................3411 2.1 Diagnosis on Accident Vehicles.......................................................................................................................................................................3411 2.2 Conditions in Which Body and/or Parts are Passed for Painting........................................................................................................................................3411 2.3 Straightening........................................................................................................................................................................................3411 2.4 Parting Cuts.........................................................................................................................................................................................3411 2.5 Replacement Body Sub-Parts and Part Sections.........................................................................................................................................................3412 2.6 Original Joint.......................................................................................................................................................................................3412 2.7 Galvanized Body Parts................................................................................................................................................................................3412 2.8 Removing Material Remains............................................................................................................................................................................3412 2.9 New Parts............................................................................................................................................................................................3412 2.10 Service Parts.......................................................................................................................................................................................3413 3 Symbols....................................................................................................................................................................................................3414 3.1 Symbols for Welding Operations.......................................................................................................................................................................3414 3.2 Symbols for Working Procedures.......................................................................................................................................................................3414 4 Body Repair Tools..........................................................................................................................................................................................3416 5 Materials for Body Repairs and General Body Repairs........................................................................................................................................................3421 5.1 Adhesives............................................................................................................................................................................................3421 5.2 Sealants.............................................................................................................................................................................................3424 5.3 Locking Fluids.......................................................................................................................................................................................3425 5.4 Surface Protection Materials.........................................................................................................................................................................3425 5.5 Anti-Corrosion Materials.............................................................................................................................................................................3426 5.6 Chemical Materials...................................................................................................................................................................................3426 5.7 Filling Materials....................................................................................................................................................................................3427 6 Bodywork - Bonded Joints...................................................................................................................................................................................3428 6.1 EuroVan from MY 1991.................................................................................................................................................................................3428 6.1.2 Bonding Procedure..............................................................................................................................................................................3428 6.2 Types of Bonded Joints...............................................................................................................................................................................3428 6.2.1 Strength Bonded Joints.........................................................................................................................................................................3428 6.2.2 Spot Welded Bonded Joints......................................................................................................................................................................3429 6.3 Repair Remedies for Partial Repairs..................................................................................................................................................................3429 6.3.1 RP Spot Welding and Bonding....................................................................................................................................................................3429 6.3.2 SG Welding and Bonding (Spot Welding Not Possible).............................................................................................................................................3429 6.3.3 Extraction of Weld Fumes.......................................................................................................................................................................3429 6.3.4 Preparation....................................................................................................................................................................................3429 6.3.5 Supplementary Work.............................................................................................................................................................................3429 6.3.6 Instructions for DA 001 730 A1.................................................................................................................................................................3430 7 Anti-Corrosion Measures....................................................................................................................................................................................3431 7.1 Anti-Corrosion Protection............................................................................................................................................................................3431 7.2 Long-Term Body Protection............................................................................................................................................................................3431 7.3 Electrolytic Galvanizing.............................................................................................................................................................................3432 7.4 Hot Galvanizing......................................................................................................................................................................................3432 8 Disposal Information.......................................................................................................................................................................................3433 8.1 Environmental Protection Practiced During Production.................................................................................................................................................3433 8.1.1 Recycling......................................................................................................................................................................................3433 8.1.2 Basic Environmental Protection Rules...........................................................................................................................................................3433 8.2 Recycling............................................................................................................................................................................................3433 8.3 Plastics.............................................................................................................................................................................................3434 8.3.1 Table 1- Frequently Used Base Polymers (Thermo- and Duroplastics)*.............................................................................................................................3434 8.3.2 Continuation of Table 1*.......................................................................................................................................................................3434 8.3.3 Table 2- Frequently Used Fillers and Reinforcing Materials*....................................................................................................................................3435 8.3.4 Table 3- Frequently Used Elastomer-Base Polymers*..............................................................................................................................................3435 8.4 Disposal.............................................................................................................................................................................................3435 8.5 Releasing Gas from Strut.............................................................................................................................................................................3436 8.6 Airbag...............................................................................................................................................................................................3436 8.6.1 Disposal.......................................................................................................................................................................................3437 9 Repair Procedures..........................................................................................................................................................................................3438 9.1 Accident Repairs.....................................................................................................................................................................................3438 10 Contact Corrosion Protection..............................................................................................................................................................................3440 10.1 Connections/Joints of Aluminum/Magnesium and Steel..................................................................................................................................................3440 11 Sheet Metal Repairs.......................................................................................................................................................................................3441 11.1 Strengthened Steel Body Panels......................................................................................................................................................................3441 11.2 Galvanized Body Parts...............................................................................................................................................................................3442 11.2.1 Preparation...................................................................................................................................................................................3442 11.2.2 Parting Cuts..................................................................................................................................................................................3442 11.2.3 Joint Techniques..............................................................................................................................................................................3442 11.3 Welding Galvanized Body Panels......................................................................................................................................................................3442 11.3.1 SG Inert Gas Welding of Galvanized Panels.....................................................................................................................................................3442 11.3.2 RP Welding of Galvanized Panels...............................................................................................................................................................3443 11.3.3 Welding Transformer...........................................................................................................................................................................3443 11.3.4 Welding Tongs.................................................................................................................................................................................3443 11.4 Unbuttoning Test....................................................................................................................................................................................3443 12 Aluminum Repairs..........................................................................................................................................................................................3444 12.1 Paint...............................................................................................................................................................................................3444 12.2 Surface Preparation.................................................................................................................................................................................3444 12.3 Removing Dents......................................................................................................................................................................................3445 12.4 Temperature Regulation for Heat Treatment...........................................................................................................................................................3445 13 Procedures for Repair of Synthetic Materials..............................................................................................................................................................3446 13.1 Materials...........................................................................................................................................................................................3446 13.2 Servicing Dents.....................................................................................................................................................................................3448 13.3 Servicing Scratches.................................................................................................................................................................................3450 13.4 Servicing Cracks (up to 100 mm).....................................................................................................................................................................3452 13.5 Servicing Holes (up to 30 mm diameter)..............................................................................................................................................................3455 13.6 Synthetic Material Repairs (Fiberglass Materials)...................................................................................................................................................3458 14 Repairing Procedure.......................................................................................................................................................................................3459 14.1 Repair Procedure....................................................................................................................................................................................3459 14.1.1 Servicing Rupture/Hole........................................................................................................................................................................3460 14.1.2 Applying Fiberglass Mats......................................................................................................................................................................3460 14.1.3 Servicing Damaged Surfaces....................................................................................................................................................................3461 15 Repairing Glass...........................................................................................................................................................................................3462 15.1 Repairing Windshields...............................................................................................................................................................................3462 15.1.1 Prerequisites.................................................................................................................................................................................3462 15.1.2 Special Tools and Workshop Equipment Required.................................................................................................................................................3463 15.1.3 Description of Repairs........................................................................................................................................................................3464 08-03 General Paint Information..................................................................................................................................................................................3470 00 – General, Technical Data.................................................................................................................................................................................3476 1 Safety Precautions.....................................................................................................................................................................................3476 1.1 Safety Precautions when Painting Vehicles with Natural Gas.......................................................................................................................................3476 1.2 Safety Precautions when Painting Vehicles with Electric Drive....................................................................................................................................3477 2 General Information....................................................................................................................................................................................3478 2.1 Factory Paint Paint Structure....................................................................................................................................................................3478 2.2 Customer Service Paint Paint Structure...........................................................................................................................................................3479 2.3 Reduced Paint Structure in Engine Compartment and Inner Hood.....................................................................................................................................3482 2.4 Repair Instructions for the Underbody and Stone Chip Protection..................................................................................................................................3482 2.5 Pretreatment of the Adhesive Surface with Two-Part Epoxy Primer Filler when Replacing Laser-Welded Roofs.........................................................................................3484 2.6 Fender Corrosion Repair Measures, in Wheel Housing Liner Contact Area............................................................................................................................3485 2.7 Fold Corrosion Servicing Notes...................................................................................................................................................................3486 2.8 Corrosion Protection for Body, Attached and Welded Parts.........................................................................................................................................3488 3 Original Products......................................................................................................................................................................................3490 3.1 General Application Instructions for Repair and Painting Systems.................................................................................................................................3490 3.1.1 Aqua Premium Application Instructions for Water-Soluble Products...........................................................................................................................3490 3.1.2 Gloss Level Adjustment of HS Clear Lacquer and HS Top Coat.................................................................................................................................3493 3.1.3 Repair Paint System for Matte Painted Vehicles.............................................................................................................................................3501 3.1.4 Paint System for Plastic Parts.............................................................................................................................................................3506 3.1.5 Aqua Premium System, Touch-Up System for Two Layer Colors..................................................................................................................................3512 3.1.6 Aqua Premium System, Touch-Up System for Three Layer Colors................................................................................................................................3517 3.1.7 Aquaplus Design and Multi-Color Paintwork..................................................................................................................................................3522 3.2 Filling Paste....................................................................................................................................................................................3526 3.2.1 Two-Part Steel Filling Paste Set...........................................................................................................................................................3526 3.2.2 Two-Part Fine Filling Paste................................................................................................................................................................3529 3.2.3 Two-Part Fine Filling Paste, Flexible......................................................................................................................................................3532 3.2.4 Two-Part Spray Filling Paste...............................................................................................................................................................3535 3.2.5 Two-Part IR Premium Filling Paste..........................................................................................................................................................3539 3.2.6 Two-Part Diamond Aluminum Filling Paste....................................................................................................................................................3543 3.3 Primer Metal.....................................................................................................................................................................................3545 3.3.1 One-Part Anti-Corrosion Wash Primer........................................................................................................................................................3545 3.3.2 One-Part Wash Primer.......................................................................................................................................................................3549 3.3.3 Two-Part Wash Primer.......................................................................................................................................................................3553 3.4 Plastic Primer...................................................................................................................................................................................3556 3.4.1 Adhesion Promoter (Glazing)................................................................................................................................................................3556 3.5 Filler...........................................................................................................................................................................................3560 3.5.1 Two-Part HS Vario Filler...................................................................................................................................................................3560 3.5.2 Two-Part HS Premium Filler.................................................................................................................................................................3568 3.5.3 Two-Part HS Mixed Filler...................................................................................................................................................................3575 3.5.4 Two-Part HS Performance Filler.............................................................................................................................................................3587 3.5.5 Two-Part Synthetic Adhesion Filler.........................................................................................................................................................3593 3.5.6 Two-Part HS Wet-in-Wet Filler..............................................................................................................................................................3598 3.6 Top Coats........................................................................................................................................................................................3602 3.6.1 Two-Part HS Top Coat.......................................................................................................................................................................3602 3.6.2 Aquaplus System (Solid and Metallic).......................................................................................................................................................3608 3.6.3 Aquaplus System (Pearl Effect and Heliochrome).............................................................................................................................................3615 3.6.4 Aquaplus Touch-Up System...................................................................................................................................................................3621 3.6.5 Aqua Premium System........................................................................................................................................................................3625 3.6.6 Aqua Premium Touch-Up System...............................................................................................................................................................3635 3.6.7 Aqua Premium System (Rim Paintwork)........................................................................................................................................................3640 3.7 Clear Coats......................................................................................................................................................................................3647 3.7.1 Two-Part HS Clear Coat.....................................................................................................................................................................3647 3.7.2 Two-Part MS Matt Clear Coat................................................................................................................................................................3653 3.7.3 Two-Part HS Vario Clear Coat...............................................................................................................................................................3656 3.7.4 Two-Part HS Optimum Clear Coat.............................................................................................................................................................3662 3.7.5 Two-Part HS Optimum Plus Clear Coat........................................................................................................................................................3665 3.7.6 Two-Part Brilliant Clear Coat..............................................................................................................................................................3669 3.7.7 Two-Part HS Brilliant Plus Clear Coat......................................................................................................................................................3673 3.7.8 Two-Part HS Performance Clear Coat.........................................................................................................................................................3678 3.7.9 Blender....................................................................................................................................................................................3682 3.8 Hardener.........................................................................................................................................................................................3686 3.8.1 Two-Part HS Hardener.......................................................................................................................................................................3686 3.8.2 Two-Part VHS Hardener and Two-Part VHS Performance Hardener................................................................................................................................3690 3.8.3 Two-Part Adhesive Filler Hardener..........................................................................................................................................................3694 3.8.4 Aqua Premium Hardener......................................................................................................................................................................3694 3.9 Thinners.........................................................................................................................................................................................3694 3.9.1 Two-Part Thinner...........................................................................................................................................................................3694 3.9.2 HS Spot Thinner............................................................................................................................................................................3698 3.9.3 Purified Water.............................................................................................................................................................................3700 3.10 Preservation....................................................................................................................................................................................3700 3.10.1 Preserving Wax............................................................................................................................................................................3700 3.10.2 Cavity Sealant............................................................................................................................................................................3701 3.10.3 Preserving Wax (Spray Can)................................................................................................................................................................3704 3.11 Underbody Protection............................................................................................................................................................................3705 3.11.1 Long-Term Underbody Protection -D 314 D36 M2-, Gray.......................................................................................................................................3705 3.11.2 Long-Term Underbody Protection -D 314 D37 M2-, Black......................................................................................................................................3708 3.11.3 Long-Term Underbody Protection -D 314 D38 M2-, Bright Color...............................................................................................................................3711 3.12 Stone Chip Protection...........................................................................................................................................................................3714 3.12.1 Stone Chip Protection -AKR 311 KD1 05-....................................................................................................................................................3714 3.12.2 Stone Chip Protection -AKR 311 KD1 10-....................................................................................................................................................3716 3.13 Wax Underbody Protection........................................................................................................................................................................3721 3.13.1 Wax Underbody Protection -D 316 D38 A2-...................................................................................................................................................3721 3.13.2 Wax Underbody Protection -D 316 000 A1-...................................................................................................................................................3723 3.13.3 Wax Spray -D 322 100 M2-..................................................................................................................................................................3724 3.14 Sealing Materials...............................................................................................................................................................................3726 3.14.1 Polyurethane Adhesive Sealant.............................................................................................................................................................3726 3.14.2 Sprayable Sealant.........................................................................................................................................................................3728 3.14.3 Adhesive/Sealant..........................................................................................................................................................................3731 3.15 Cleaning Agent..................................................................................................................................................................................3734 3.15.1 Silicone Remover..........................................................................................................................................................................3734 3.15.2 Plastic Cleaner...........................................................................................................................................................................3735 3.15.3 Antistatic Plastic Cleaner................................................................................................................................................................3736 3.15.4 Industrial Dirt Remover...................................................................................................................................................................3737 3.16 SprayMax System.................................................................................................................................................................................3738 3.16.1 One-Part Anti-Corrosion Primer............................................................................................................................................................3738 3.16.2 One-Part Test Paint.......................................................................................................................................................................3741 3.16.3 One-Part Clear Coat.......................................................................................................................................................................3743 3.16.4 One-Part Wash Primer......................................................................................................................................................................3746 3.16.5 One-Part Clean Spray Can -LLS MAX 099-, -LLS MAX 100-, Aquaplus System....................................................................................................................3749 3.16.6 One-Part Clean Spray Can -LLS MAX 112-, Aqua Premium System...............................................................................................................................3755 3.16.7 Two-Part Filler...........................................................................................................................................................................3762 3.16.8 Two-Part Clear Coat.......................................................................................................................................................................3768 3.16.9 Two-Part Epoxy Primer Filler..............................................................................................................................................................3772 3.16.10 Two-Part Wash Primer.....................................................................................................................................................................3777 3.16.11 Silicone Remover -LLS MAX 007-...........................................................................................................................................................3781 3.16.12 Silicone Remover, Long -LLS MAX 008-.....................................................................................................................................................3784 3.16.13 Blender..................................................................................................................................................................................3785 3.16.14 Bonding Agent............................................................................................................................................................................3787 3.17 Additional Materials............................................................................................................................................................................3790 3.17.1 Matting Component - ALN 775 106-..........................................................................................................................................................3790 3.17.2 Matting Component -LVM 769 810 A2-........................................................................................................................................................3796 3.17.3 Structuring Component.....................................................................................................................................................................3799 3.17.4 Aquaplus Touch-Up Additive................................................................................................................................................................3804 3.17.5 Aqua Premium System Additive..............................................................................................................................................................3804 4 Workshop Equipment.....................................................................................................................................................................................3806 4.1 Tools............................................................................................................................................................................................3806 4.1.1 Spray Can Filling Device -VAS6425-.........................................................................................................................................................3806 4.1.2 Paint Thickness Tester -VAS6272-...........................................................................................................................................................3807 4.1.3 Paint Thickness Tester -VAS6197-...........................................................................................................................................................3807 4.1.4 Paint Thickness Test -VAS5278-.............................................................................................................................................................3807 4.1.5 Stone Chip Tester -VAS5102A-...............................................................................................................................................................3809 4.1.6 Pneumatic Brush Grinder Set -VAS6446-......................................................................................................................................................3810 4.1.7 Brush Grinder Set -VAS6776-................................................................................................................................................................3811 4.1.8 Suction Feed Spray Gun -VAG1538-...........................................................................................................................................................3812 4.1.9 Infrared Dryer -VAS6873-...................................................................................................................................................................3813 4.1.10 Stand -VAS6873/1-.........................................................................................................................................................................3813 4.1.11 Infrared Dryer -VAS6874-..................................................................................................................................................................3814 4.1.12 Infrared Dryer -VAS6875-..................................................................................................................................................................3814 4.1.13 Infrared Dryer -VAS6876-..................................................................................................................................................................3815 4.1.14 Infrared Dryer -VAS6877-..................................................................................................................................................................3816 4.1.15 Infrared Dryer -VAS6878-..................................................................................................................................................................3817 4.1.16 Infrared Dryer -VAS6879-..................................................................................................................................................................3818 4.2 Dust Cloths......................................................................................................................................................................................3818 4.2.1 Dust Cloth -VAS6177-.......................................................................................................................................................................3818 4.2.2 White Polishing Cloth -VAS6176-............................................................................................................................................................3819 4.2.3 Primary Duster -VAS5542-...................................................................................................................................................................3819 4.2.4 Professional Cleaning Cloth -VAS6006-......................................................................................................................................................3820 5 Revision History.......................................................................................................................................................................................3821 08-04-Paint......................................................................................................................................................................................................3825 00 – General, Technical Data.................................................................................................................................................................................3829 1 Symbol Explanations....................................................................................................................................................................................3829 1.1 Sanding..........................................................................................................................................................................................3829 1.2 Weld Sealant.....................................................................................................................................................................................3829 1.3 Cavity Sealants..................................................................................................................................................................................3831 2 Paint System...........................................................................................................................................................................................3832 2.1 Factory Paint Paint Structure, KTL Primer........................................................................................................................................................3832 2.2 Factory Paint Paint Structure, Filler............................................................................................................................................................3834 2.3 Factory Paint Paint Structure, Base Paint........................................................................................................................................................3836 2.4 Factory Paint Paint Structure, Clear Lacquer.....................................................................................................................................................3838 3 Stone Impact Vulnerable Areas..........................................................................................................................................................................3840 3.1 Stone Impact Vulnerable Areas on the Body........................................................................................................................................................3840 4 Cover Points...........................................................................................................................................................................................3842 4.1 Front Body Cover Points..........................................................................................................................................................................3842 4.2 Rear Body Cover Points...........................................................................................................................................................................3850 4.3 Body Cover Points, Also on CNG Vehicles (Gasoline Vehicles)......................................................................................................................................3857 5 Weld Sealant...........................................................................................................................................................................................3858 5.1 Front Body Weld Sealant..........................................................................................................................................................................3858 5.2 Body Center Weld Sealant.........................................................................................................................................................................3867 5.3 Rear Body Weld Sealant...........................................................................................................................................................................3873 5.4 Body Weld Sealant, Also on CNG Vehicles (Gasoline Vehicles)......................................................................................................................................3886 5.5 Body Weld Sealant, Additionally e-Golf...........................................................................................................................................................3887 5.6 Body Weld Sealant, Also on Hybrid Vehicles.......................................................................................................................................................3890 6 Underbody Protection...................................................................................................................................................................................3893 6.1 Underbody Protection Protected Areas, Body Overview with different Coating Densities.............................................................................................................3893 6.2 Underbody Protection Protected Areas.............................................................................................................................................................3894 6.3 Underbody Protection Areas, Also On CNG Vehicles (Gasoline Vehicles).............................................................................................................................3899 6.4 Underbody Protection Areas, Also on eGolf........................................................................................................................................................3900 6.5 Underbody Protection Areas, Also On Hybrid Vehicles..............................................................................................................................................3903 7 Cavity Sealants........................................................................................................................................................................................3904 7.1 Cavity Sealants, Overall Body View...............................................................................................................................................................3904 7.2 Cavity Sealants, Front and Center Body...........................................................................................................................................................3905 7.3 Cavity Sealants, Body Rear.......................................................................................................................................................................3907 7.4 Cavity Sealants, Body General View, eGolf........................................................................................................................................................3910 7.5 Cavity Sealants, Body General View, Hybrid Vehicle...............................................................................................................................................3912 8 Revision History.......................................................................................................................................................................................3913 08-05 Body Exterior..............................................................................................................................................................................................3917 50 – Body Front..............................................................................................................................................................................................3925 1 Lock Carrier...........................................................................................................................................................................................3925 1.1 Overview - Lock Carrier..........................................................................................................................................................................3925 1.1.1 Overview - Lock Carrier....................................................................................................................................................................3925 1.1.2 Overview - Lock Carrier....................................................................................................................................................................3927 1.2 Lock Carrier, Removing and Installing............................................................................................................................................................3927 1.2.1 Lock Carrier, Removing and Installing, Gasoline/Diesel.....................................................................................................................................3928 1.2.2 Lock Carrier, Removing and Installing - e-Golf.............................................................................................................................................3929 1.3 Service Position, Performing and Resetting.......................................................................................................................................................3931 1.4 Lock Carrier, Servicing..........................................................................................................................................................................3934 1.4.1 Left Headlamp Mount........................................................................................................................................................................3934 1.4.2 Right Headlamp Mount.......................................................................................................................................................................3936 2 Fender.................................................................................................................................................................................................3937 2.1 Overview - Fender................................................................................................................................................................................3937 2.2 Overview - Deformation Element...................................................................................................................................................................3938 2.3 Fender, Removing and Installing..................................................................................................................................................................3938 2.4 Fender Brace, Removing and Installing............................................................................................................................................................3941 3 Bulkhead...............................................................................................................................................................................................3943 3.1 Overview - Bulkhead..............................................................................................................................................................................3943 3.2 Overview - Plenum Chamber Cover..................................................................................................................................................................3944 3.3 Bulkhead, Removing and Installing................................................................................................................................................................3944 3.4 Plenum Chamber Cover, Removing and Installing....................................................................................................................................................3946 4 Special Tools..........................................................................................................................................................................................3949 55 – Hood, Lids..............................................................................................................................................................................................3951 1 Hood...................................................................................................................................................................................................3951 1.1 Overview - Hood..................................................................................................................................................................................3951 1.2 Overview - Release Cable.........................................................................................................................................................................3953 1.3 Hood, Removing and Installing....................................................................................................................................................................3953 1.4 Hood, Adjusting..................................................................................................................................................................................3955 1.5 Hood Latch, Removing and Installing..............................................................................................................................................................3960 1.5.1 Hood Latch, Removing and Installing........................................................................................................................................................3960 1.5.2 Hood Latch, Removing and Installing, RHD...................................................................................................................................................3962 1.6 Hood Release Lever, Removing and Installing......................................................................................................................................................3965 1.7 Catch, Removing and Installing...................................................................................................................................................................3966 1.8 Hinges, Removing and Installing..................................................................................................................................................................3968 1.9 Insulation, Removing and Installing..............................................................................................................................................................3970 1.10 Gas-Filled Strut, Removing and Installing.......................................................................................................................................................3973 1.11 Gas-Filled Strut, Releasing Gas.................................................................................................................................................................3974 1.12 Release Cable, Removing and Installing..........................................................................................................................................................3974 2 Rear Lid...............................................................................................................................................................................................3978 2.1 Overview - Rear Lid..............................................................................................................................................................................3978 2.2 Rear Lid, Removing and Installing................................................................................................................................................................3979 2.3 Rear Lid, Adjusting..............................................................................................................................................................................3981 2.4 Hood Latch, Removing and Installing..............................................................................................................................................................3986 2.5 Actuator, Removing and Installing................................................................................................................................................................3988 2.5.1 Actuator, Removing and Installing, without Rearview Camera.................................................................................................................................3988 2.5.2 Actuator, Removing and Installing, with Rearview Camera....................................................................................................................................3990 2.6 Hinges, Removing and Installing..................................................................................................................................................................3992 2.7 Catch, Removing and Installing...................................................................................................................................................................3994 2.8 Rear Lid Seal, Removing and Installing...........................................................................................................................................................3995 2.9 Gas-Filled Strut, Removing and Installing........................................................................................................................................................3997 2.10 Gas-Filled Strut, Releasing Gas.................................................................................................................................................................3999 3 Fuel Filler Door Unit..................................................................................................................................................................................4000 3.1 Overview - Fuel Filler Door Unit.................................................................................................................................................................4000 3.2 Overview - Fuel Filler Door Unit, e-Golf.........................................................................................................................................................4001 3.3 Fuel Filler Door Unit, Removing and Installing...................................................................................................................................................4001 3.4 Fuel Filler Door Unit, Removing and Installing, e-Golf...........................................................................................................................................4003 3.5 Fuel Filler Door, Removing and Installing........................................................................................................................................................4007 3.6 Adjusting Element, Removing and Installing.......................................................................................................................................................4008 4 Special Tools..........................................................................................................................................................................................4009 57 – Front Doors, Central Locking System.....................................................................................................................................................................4010 1 Door...................................................................................................................................................................................................4010 1.1 Overview - Door..................................................................................................................................................................................4010 1.2 Inner Door Seal, Removing and Installing.........................................................................................................................................................4013 1.3 Outer Door Seal, Removing and Installing.........................................................................................................................................................4016 1.3.1 Outer Door Seal, Removing and Installing, 4-Door Vehicle...................................................................................................................................4016 1.3.2 Outer Door Seal, Removing and Installing, 2-Door Vehicle...................................................................................................................................4017 1.4 Door, Removing and Installing....................................................................................................................................................................4017 1.5 Door, Adjusting..................................................................................................................................................................................4020 1.6 Catch, Adjusting.................................................................................................................................................................................4022 1.7 Door Arrester, Removing and Installing...........................................................................................................................................................4024 2 Door Components........................................................................................................................................................................................4026 2.1 Overview - Door Components.......................................................................................................................................................................4026 2.2 Overview - Window Regulator......................................................................................................................................................................4028 2.3 Overview - Door Handle and Door Lock.............................................................................................................................................................4029 2.4 Left and Right Window Regulator Motor -V14-/-V15-, Removing and Installing.......................................................................................................................4030 2.5 Window Regulator, Removing and Installing........................................................................................................................................................4032 2.6 Door Inner Cover, Removing and Installing........................................................................................................................................................4035 2.7 Catch, Removing and Installing...................................................................................................................................................................4037 2.8 Cap, Removing and Installing, for the Lock Cylinder..............................................................................................................................................4037 2.9 Cap, Removing and Installing, without the Lock Cylinder..........................................................................................................................................4039 2.10 Lock Cylinder, Removing and Installing..........................................................................................................................................................4043 2.11 Door Handle, Removing and Installing............................................................................................................................................................4045 2.12 Bracket, Removing and Installing................................................................................................................................................................4047 2.13 Door Lock, Removing and Installing..............................................................................................................................................................4050 2.14 Window Guide, Removing and Installing...........................................................................................................................................................4054 2.15 Outer Window Shaft Strip, Removing and Installing...............................................................................................................................................4057 2.16 Inner Window Shaft Strip, Removing and Installing...............................................................................................................................................4059 3 Central Locking........................................................................................................................................................................................4060 3.1 Component Location Overview - Central Locking....................................................................................................................................................4060 3.2 Vehicle Key Battery, Removing and Installing.....................................................................................................................................................4062 3.3 Ignition Key Cap, Removing and Installing........................................................................................................................................................4064 4 Special Tools..........................................................................................................................................................................................4065 58 – Rear Doors..............................................................................................................................................................................................4066 1 Door...................................................................................................................................................................................................4066 1.1 Overview - Door..................................................................................................................................................................................4066 1.2 Door, Removing and Installing....................................................................................................................................................................4068 1.3 Door, Adjusting..................................................................................................................................................................................4071 1.4 Catch, Adjusting.................................................................................................................................................................................4073 1.5 Door Arrester, Removing and Installing...........................................................................................................................................................4074 1.6 Inner Door Seal, Removing and Installing.........................................................................................................................................................4076 2 Door Components........................................................................................................................................................................................4079 2.1 Overview - Door Components.......................................................................................................................................................................4079 2.2 Overview - Window Regulator......................................................................................................................................................................4081 2.3 Overview - Door Handle and Door Lock.............................................................................................................................................................4082 2.4 Left and Right Rear Window Regulator Motor -V26-/-V27-, Removing and Installing..................................................................................................................4083 2.5 Window Regulator, Removing and Installing........................................................................................................................................................4085 2.6 Window Crank, Removing and Installing............................................................................................................................................................4088 2.7 Door Inner Cover, Removing and Installing........................................................................................................................................................4090 2.8 Catch, Removing and Installing...................................................................................................................................................................4092 2.9 Cap, Removing and Installing.....................................................................................................................................................................4093 2.10 Door Handle, Removing and Installing............................................................................................................................................................4095 2.11 Bracket, Removing and Installing................................................................................................................................................................4097 2.12 Door Lock, Removing and Installing..............................................................................................................................................................4099 2.13 Window Guide, Removing and Installing...........................................................................................................................................................4103 2.14 Outer Window Shaft Strip, Removing and Installing...............................................................................................................................................4106 2.15 Inner Window Shaft Strip, Removing and Installing...............................................................................................................................................4107 3 Special Tools..........................................................................................................................................................................................4109 60 – Sunroof.................................................................................................................................................................................................4110 1 Sunroof................................................................................................................................................................................................4110 1.1 Overview - Sunroof...............................................................................................................................................................................4110 1.2 Overview - Sunroof Shade.........................................................................................................................................................................4113 1.3 Sunroof Frame, Removing and Installing...........................................................................................................................................................4113 1.4 Wind Deflector, Removing and Installing..........................................................................................................................................................4121 1.5 Glass Panel, Removing and Installing.............................................................................................................................................................4123 1.5.1 Glass Panel, Removing and Installing.......................................................................................................................................................4123 1.5.2 Glass Panel, Removing, Defective Drive Motor...............................................................................................................................................4127 1.6 Glass Panel, Adjusting...........................................................................................................................................................................4128 1.7 Slotted Guide Rail Guide, Removing and Installing................................................................................................................................................4130 1.8 Sliding Sunroof Front Trim, Removing and Installing..............................................................................................................................................4133 1.9 Power Sunroof Control Module -J245-, Removing and Installing.....................................................................................................................................4139 1.10 Sunroof, Closing Manually.......................................................................................................................................................................4143 1.11 Sunroof Seals, Removing and Installing..........................................................................................................................................................4145 1.11.1 Sunroof Frame Seal, Removing and Installing...............................................................................................................................................4145 1.11.2 Glass Panel Seal, Removing and Installing.................................................................................................................................................4146 1.12 Sunroof Shade, Removing and Installing..........................................................................................................................................................4146 1.13 Power Sunroof Control Module -J245-, Programming................................................................................................................................................4156 2 Water Drain Hoses......................................................................................................................................................................................4157 2.1 Overview - Water Drain Hoses.....................................................................................................................................................................4157 2.2 Water Drain Hoses, Cleaning......................................................................................................................................................................4157 2.3 Water Drain Hoses, Removing and Installing.......................................................................................................................................................4159 3 Special Tools..........................................................................................................................................................................................4161 63 – Bumpers.................................................................................................................................................................................................4163 1 Front Bumper...........................................................................................................................................................................................4163 1.1 Overview - Bumper Cover..........................................................................................................................................................................4163 1.2 Overview - Attachments...........................................................................................................................................................................4164 1.2.1 Overview - Attachments.....................................................................................................................................................................4164 1.2.2 Overview - Attachments, GTI/GTD............................................................................................................................................................4166 1.2.3 Overview - Attachments, “e-Golf” and “GTE”.................................................................................................................................................4168 1.2.4 Overview - Attachments, “R-Line”...........................................................................................................................................................4169 1.2.5 Overview - Attachments, “R”................................................................................................................................................................4170 1.3 Overview - Impact Absorber.......................................................................................................................................................................4172 1.4 Bumper Cover, Removing and Installing............................................................................................................................................................4172 1.5 Bumper Cover, Servicing..........................................................................................................................................................................4175 1.6 Parking Aid Mount, Installing....................................................................................................................................................................4175 2 Rear Bumper............................................................................................................................................................................................4180 2.1 Overview - Bumper Cover..........................................................................................................................................................................4180 2.2 Overview - Bumper Cover Guides...................................................................................................................................................................4181 2.3 Overview - Attachments...........................................................................................................................................................................4182 2.3.1 Overview - Attachments.....................................................................................................................................................................4182 2.3.2 Overview - Attachments, GTI/GTD............................................................................................................................................................4183 2.3.3 Overview - Attachments, “R-Line”...........................................................................................................................................................4184 2.3.4 Overview - Attachments, “R”................................................................................................................................................................4185 2.3.5 Overview - Wheel Housing Liner Bracket Adapter “R-Line” and “R”............................................................................................................................4186 2.4 Overview - Impact Absorber.......................................................................................................................................................................4186 2.5 Bumper Cover, Removing and Installing............................................................................................................................................................4187 2.6 Impact Member, Removing and Installing...........................................................................................................................................................4191 2.7 Bumper Cover, Servicing..........................................................................................................................................................................4192 2.8 Parking Aid Mount, Installing....................................................................................................................................................................4192 3 Special Tools..........................................................................................................................................................................................4197 64 – Glass, Window Regulators................................................................................................................................................................................4198 1 Repair Information.....................................................................................................................................................................................4198 1.1 Minimum Curing Time for Bonded Windows...........................................................................................................................................................4198 1.2 Window Glass, Servicing..........................................................................................................................................................................4198 1.3 Bonded Window Glass Installation Instructions....................................................................................................................................................4199 1.3.1 Installation Instructions..................................................................................................................................................................4199 1.3.2 Materials..................................................................................................................................................................................4199 1.4 Undamaged Window Glass, Preparing for Installation...............................................................................................................................................4200 1.5 New Window Glass, Preparing for Installation.....................................................................................................................................................4201 1.6 Body Flange, Preparing for Installation..........................................................................................................................................................4202 1.7 Adhesive, Removing...............................................................................................................................................................................4203 2 Windshield.............................................................................................................................................................................................4205 2.1 Overview - Windshield............................................................................................................................................................................4205 2.2 Windshield, Removing and Installing..............................................................................................................................................................4206 2.2.1 Windshield, Removing and Installing........................................................................................................................................................4206 2.2.2 Damaged Windshield, Removing...............................................................................................................................................................4212 3 Rear Window............................................................................................................................................................................................4213 3.1 Overview - Rear Window...........................................................................................................................................................................4213 3.2 Rear Window, Removing and Installing.............................................................................................................................................................4214 3.2.1 Rear Window, Removing and Installing.......................................................................................................................................................4214 3.2.2 Damaged Rear Window, Removing..............................................................................................................................................................4217 4 Side Windows...........................................................................................................................................................................................4218 4.1 Overview - Front Side Window.....................................................................................................................................................................4218 4.2 Overview - Rear Side Window......................................................................................................................................................................4219 4.3 Front Side Window, Removing and Installing.......................................................................................................................................................4219 4.3.1 Front Side Window, Removing and Installing.................................................................................................................................................4219 4.3.2 Damaged Front Side Window, Removing........................................................................................................................................................4221 4.4 Rear Side Window, Removing and Installing........................................................................................................................................................4221 4.4.1 Rear Side Window, Removing and Installing..................................................................................................................................................4221 4.4.2 Damaged Rear Side Window, Removing.........................................................................................................................................................4223 5 Door Windows...........................................................................................................................................................................................4224 5.1 Overview - Front Door Window.....................................................................................................................................................................4224 5.2 Overview - Rear Door Window......................................................................................................................................................................4225 5.3 Overview - Fixed Rear Door Window................................................................................................................................................................4226 5.4 Front Door Window, Removing and Installing.......................................................................................................................................................4226 5.5 Rear Door Window, Removing and Installing........................................................................................................................................................4230 5.6 Rear Fixed Door Window, Removing and Installing..................................................................................................................................................4234 6 Special Tools..........................................................................................................................................................................................4236 66 – Exterior Equipment......................................................................................................................................................................................4237 1 Radiator Grille/Front Trim.............................................................................................................................................................................4237 1.1 Overview - Radiator Grille.......................................................................................................................................................................4237 1.2 Overview - Charging Port Door....................................................................................................................................................................4238 1.3 Radiator Grille, Removing and Installing.........................................................................................................................................................4238 1.4 Charging Port Door, Removing and Installing......................................................................................................................................................4240 1.5 Adjusting Element, Removing and Installing.......................................................................................................................................................4243 2 Spoiler................................................................................................................................................................................................4245 2.1 Overview - Spoiler on the Edge of the Roof.......................................................................................................................................................4245 2.2 Overview - Side Spoiler..........................................................................................................................................................................4246 2.3 Roof Edge Spoiler, Removing and Installing.......................................................................................................................................................4246 2.4 Side Spoiler, Removing and Installing............................................................................................................................................................4249 3 Molding/Trim/Extensions/Trim Panels....................................................................................................................................................................4254 3.1 Overview - Drip Rail.............................................................................................................................................................................4254 3.2 Overview - Sill Panel Trim.......................................................................................................................................................................4256 3.2.1 Overview - Sill Panel Trim, GTI/GTD........................................................................................................................................................4256 3.2.2 Overview - Sill Panel Trim, “R”, North American Region.....................................................................................................................................4257 3.2.3 Overview - Sill Panel Trim, “R-Line” and “R”...............................................................................................................................................4258 3.3 Overview - Heat Shield...........................................................................................................................................................................4259 3.4 Drip Rail, Removing and Installing...............................................................................................................................................................4260 3.5 Sill Panel Trim..................................................................................................................................................................................4261 3.5.1 Sill Panel Trim, Removing and Installing, GTI/GTD..........................................................................................................................................4261 3.5.2 Rocker Panel Extension, Removing and Installing, “R-Line” and “R”..........................................................................................................................4264 3.5.3 Rocker Panel Extension, Removing and Installing, “R”, North American Region................................................................................................................4268 3.5.4 Rocker Panel Extension Retaining Strip, Attaching, “R”, North American Region..............................................................................................................4271 3.6 Front Door B-Pillar Trim, Removing and Installing................................................................................................................................................4272 3.7 Rear Door B-Pillar Trim, Removing and Installing.................................................................................................................................................4274 3.8 Floor Heat Shield, Removing and Installing.......................................................................................................................................................4275 3.9 Center Exhaust System Heat Shield, Removing and Installing.......................................................................................................................................4276 3.10 Rear Muffler Heat Shield, Removing and Installing...............................................................................................................................................4277 4 Noise Insulation.......................................................................................................................................................................................4279 4.1 Overview - Noise Insulation......................................................................................................................................................................4279 4.1.1 Overview - Noise Insulation, Short.........................................................................................................................................................4279 4.1.2 Overview - Noise Insulation, Long..........................................................................................................................................................4280 4.1.3 Overview - Impact Guard....................................................................................................................................................................4281 5 Underbody Trim Panel...................................................................................................................................................................................4282 5.1 Overview - Underbody Panels......................................................................................................................................................................4282 5.1.1 Overview - Underbody Panels, Gasoline/Diesel...............................................................................................................................................4282 5.1.2 Overview - Underbody Panel, e-Golf.........................................................................................................................................................4283 5.1.3 Overview - Hybrid Underbody Panels.........................................................................................................................................................4285 5.2 Underbody Panels, Removing and Installing........................................................................................................................................................4285 5.2.1 Underbody Panels, Removing and Installing, Gasoline/Diesel.................................................................................................................................4286 5.2.2 Front Underbody Panel, Removing and Installing, e-Golf.....................................................................................................................................4287 5.3 Center Underbody Panels, Removing and Installing.................................................................................................................................................4288 5.3.1 Center Underbody Panel, Removing and Installing, Long......................................................................................................................................4288 5.3.2 Center Underbody Panel, Removing and Installing, Short.....................................................................................................................................4289 5.3.3 Center Underbody Panel, Removing and Installing, e-Golf....................................................................................................................................4290 5.4 Rear Underbody Panel, Removing and Installing....................................................................................................................................................4290 5.4.1 Rear Underbody Panel, Removing and Installing, Gasoline/Diesel.............................................................................................................................4291 5.4.2 Rear Underbody Panel, Removing and Installing, e-Golf......................................................................................................................................4292 5.5 Front Tunnel Bridge, Removing and Installing.....................................................................................................................................................4292 5.6 Rear Tunnel Bridge, Removing and Installing......................................................................................................................................................4293 6 Exterior Rearview Mirror...............................................................................................................................................................................4295 6.1 Overview - Exterior Rearview Mirror..............................................................................................................................................................4295 6.2 Exterior Rearview Mirror, Removing and Installing................................................................................................................................................4296 6.3 Mirror Glass, Removing and Installing............................................................................................................................................................4298 6.4 Mirror Adjusting Unit, Removing and Installing...................................................................................................................................................4299 6.5 Mirror Cap, Removing and Installing..............................................................................................................................................................4301 6.6 Mirror Trim, Removing and Installing.............................................................................................................................................................4302 7 Wheel Housing Liner....................................................................................................................................................................................4304 7.1 Overview - Front Wheel Housing Liner.............................................................................................................................................................4304 7.2 Overview - Rear Wheel Housing Liner..............................................................................................................................................................4305 7.3 Front Wheel Housing Liner, Removing and Installing...............................................................................................................................................4306 7.3.1 Front Wheel Housing Liner Front Section, Removing and Installing...........................................................................................................................4306 7.3.2 Entire Front Wheel Housing Liner, Removing and Installing..................................................................................................................................4307 7.4 Rear Wheel Housing Liner, Removing and Installing................................................................................................................................................4308 8 Name Badges and Emblems................................................................................................................................................................................4311 8.1 Dimensions - Rear Lid Name Badges and Emblems....................................................................................................................................................4311 8.1.1 Rear Lid Name Badge Dimension..............................................................................................................................................................4311 8.1.2 Dimension - Name Badge “GTI/GTD” on the Rear Lid...........................................................................................................................................4313 8.1.3 Dimension - Name Badge “e-Golf” on the Rear Lid............................................................................................................................................4314 8.1.4 Dimension - Name Badge “R” on the Rear Lid.................................................................................................................................................4315 8.2 Dimensions - Name Badges and Emblems on Fender...................................................................................................................................................4316 8.2.1 Dimensions - Name Badge on Fender..........................................................................................................................................................4316 8.2.2 Dimension - Name Badge on Fender “R”.......................................................................................................................................................4317 8.3 Front Emblem, Removing and Installing............................................................................................................................................................4318 8.3.1 Brand Emblem, Removing and Installing......................................................................................................................................................4318 8.3.2 Model Name on Radiator Grille, Removing and Installing.....................................................................................................................................4319 8.3.3 Model Name “R-Line”, Removing and Installing...............................................................................................................................................4320 8.3.4 Model Name “R”, Removing and Installing....................................................................................................................................................4321 8.4 Rear Emblem, Removing and Installing.............................................................................................................................................................4322 9 Other Attachments......................................................................................................................................................................................4324 9.1 Overview - Other Attachments.....................................................................................................................................................................4324 9.1.1 Overview - Other Attachments “R-Line”......................................................................................................................................................4324 9.1.2 Overview - Other Attachments “R”...........................................................................................................................................................4325 10 Trailer Hitch.........................................................................................................................................................................................4326 10.1 Overview - Trailer Hitch........................................................................................................................................................................4326 10.2 Overview - Release Cable........................................................................................................................................................................4327 10.3 Trailer Hitch, Removing and Installing..........................................................................................................................................................4328 10.4 Release Cable, Removing and Installing..........................................................................................................................................................4330 11 Special Tools.........................................................................................................................................................................................4333 12 Revision History......................................................................................................................................................................................4335 08-06 Body Interior..............................................................................................................................................................................................4339 00 – General, Technical Data.................................................................................................................................................................................4347 1 Safety Precautions.....................................................................................................................................................................................4347 1.1 Start/Stop System Safety Precautions.............................................................................................................................................................4348 1.2 Pyrotechnic Components Safety Precautions........................................................................................................................................................4349 1.3 Airbag, Belt Tensioner and Battery Cut-Out Units, Storing, Transporting and Disposing............................................................................................................4351 1.4 Side Airbag Additional Safety Precautions........................................................................................................................................................4352 1.5 Head Curtain Airbag Additional Safety Precautions................................................................................................................................................4353 1.6 Front Side Airbag Crash Sensors (Pressure Sensors) Safety Precautions............................................................................................................................4353 1.7 Passenger Occupant Detection System Deactivation Additional Safety Precautions, Market-Specific..................................................................................................4354 1.8 Passenger Safety System Pyrotechnical, Electric and Mechanical Components, Replacing After a Collision...........................................................................................4355 1.9 Airbag Fasteners, Checking After a Collision.....................................................................................................................................................4356 1.10 Collision without Airbag Deployment.............................................................................................................................................................4357 1.11 Seat Belts, Checking............................................................................................................................................................................4357 1.12 Seat Belt Webbing, Checking.....................................................................................................................................................................4358 1.13 Automatic Belt Retractor, Checking..............................................................................................................................................................4359 1.14 Seat Belt Latch, Inspecting Visually............................................................................................................................................................4359 1.15 Seat Belt Latch Function Test...................................................................................................................................................................4359 1.16 Seat Belt Relays and Latch Tongue, Checking.....................................................................................................................................................4360 1.17 Attachments and Attaching Points, Checking After a Collision....................................................................................................................................4360 1.18 Seat Belt for Child Seat, Checking Child Seat Restraint Function, Market-Specific...............................................................................................................4360 1.19 Child Seat Anchors, Checking After a Collision..................................................................................................................................................4361 1.20 Automatic Dimming Interior Rearview Mirror Safety Precautions...................................................................................................................................4361 2 Repair Information.....................................................................................................................................................................................4362 2.1 Contact Corrosion................................................................................................................................................................................4362 2.2 Wire Routing and Securing........................................................................................................................................................................4362 3 Special Tools..........................................................................................................................................................................................4363 68 – Interior Equipment......................................................................................................................................................................................4364 1 Storage Compartments and Covers........................................................................................................................................................................4364 1.1 Component Location Overview - Storage Compartment/Covers.........................................................................................................................................4364 1.2 Overview - Driver Side Footwell Cover............................................................................................................................................................4366 1.3 Overview - Driver Side Instrument Panel Cover....................................................................................................................................................4367 1.4 Overview - Steering Column Trim Panel............................................................................................................................................................4368 1.5 Overview - Glove Compartment.....................................................................................................................................................................4369 1.6 Overview - Headliner Compartment.................................................................................................................................................................4370 1.7 Driver Side Footwell Cover, Removing and Installing..............................................................................................................................................4370 1.8 Driver Side Storage Compartment, Removing and Installing.........................................................................................................................................4372 1.9 Driver Side Instrument Panel Cover, Removing and Installing......................................................................................................................................4372 1.10 Instrument Cluster Gap Cover, Removing and Installing...........................................................................................................................................4374 1.11 Upper Steering Column Trim Panel, Removing and Installing.......................................................................................................................................4374 1.12 Lower Steering Column Trim Panel, Removing and Installing.......................................................................................................................................4375 1.13 Front Passenger Side Footwell Cover, Removing and Installing....................................................................................................................................4377 1.14 Glove Compartment Handle, Removing and Installing...............................................................................................................................................4377 1.15 Glove Compartment Lid Service Position..........................................................................................................................................................4379 1.16 Glove Compartment Lid Dampening Mechanism, Removing and Installing..............................................................................................................................4379 1.17 Glove Compartment, Removing and Installing......................................................................................................................................................4380 1.18 Glove Compartment Lid, Removing and Installing..................................................................................................................................................4381 1.19 Headliner Storage Compartment, Removing and Installing..........................................................................................................................................4382 2 Equipment..............................................................................................................................................................................................4383 2.1 Overview - Screen Separator......................................................................................................................................................................4383 2.2 Overview - Sun Visors............................................................................................................................................................................4385 2.3 Overview - Roof Grab Handle......................................................................................................................................................................4386 2.4 Screen Separator, Removing and Installing........................................................................................................................................................4386 2.5 Screen Separator Mount, Removing and Installing..................................................................................................................................................4387 2.6 Screen Separator Bracket, Removing and Installing................................................................................................................................................4387 2.7 Screen Separator Mount, Removing and Installing..................................................................................................................................................4388 2.8 Sun Visor, Removing and Installing...............................................................................................................................................................4389 2.9 Sun Visor Center Support, Removing and Installing................................................................................................................................................4391 2.10 Roof Grab Handle, Removing and Installing.......................................................................................................................................................4392 2.10.1 Roof Grab Handle, Removing and Installing, 2- and 4-Door Vehicles.........................................................................................................................4392 2.10.2 Roof Grab Handle, Removing and Installing, Wagon through 01/2014..........................................................................................................................4394 2.10.3 Roof Grab Handle, Removing and Installing, Wagon from 02/2014.............................................................................................................................4396 2.11 Roof Grab Handle Bracket, Removing and Installing...............................................................................................................................................4397 3 Center Console.........................................................................................................................................................................................4399 3.1 Overview - Center Console........................................................................................................................................................................4399 3.1.1 Overview - Center Console, Basic Equipment Level...........................................................................................................................................4399 3.1.2 Overview - Center Console, Convenience Equipment Level.....................................................................................................................................4402 3.1.3 Overview - Center Console, e-Golf..........................................................................................................................................................4404 3.2 Front Ashtray, Removing and Installing...........................................................................................................................................................4406 3.3 Center Console Rear Trim, Removing and Installing................................................................................................................................................4406 3.4 Footwell Center Console Trim Panel, Removing and Installing......................................................................................................................................4406 3.5 Display and Control Unit Trim, Removing and Installing...........................................................................................................................................4408 3.6 Front Center Console Storage Compartment, Removing and Installing................................................................................................................................4408 3.7 Center Console Cover, Removing and Installing....................................................................................................................................................4408 3.8 Center Console Insert, Removing and Installing...................................................................................................................................................4409 3.9 Center Console, Removing and Installing..........................................................................................................................................................4411 3.9.1 Center Console, Removing and Installing, All Vehicles Except e-Golf........................................................................................................................4411 3.9.2 Center Console, Removing and Installing, Only e-Golf.......................................................................................................................................4413 3.10 Mounting Plate with Securing Strap, Removing and Installing.....................................................................................................................................4417 3.11 Center Console Bracket, Removing and Installing.................................................................................................................................................4417 3.11.1 Center Console Bracket, Removing and Installing, All Vehicles Except e-Golf...............................................................................................................4417 3.11.2 Center Console Bracket, Mounting Bracket and Shifting Mechanism Insulation, Removing and Installing, Only e-Golf..........................................................................4419 4 Front Center Armrest...................................................................................................................................................................................4421 4.1 Overview - Front Center Armrest..................................................................................................................................................................4421 4.2 Front Center Armrest, Removing and Installing....................................................................................................................................................4421 5 Interior Rearview Mirror...............................................................................................................................................................................4424 5.1 Overview - Interior Rearview Mirror..............................................................................................................................................................4424 5.1.1 Overview - Interior Rearview Mirror with Manual Dimming, without Rain/Light Recognition Sensor -G397- and Driver Assistance Systems Front Camera -R242-....................................4424 5.1.2 Overview - Interior Rearview Mirror with Manual or Automatic Dimming, with Rain/Light Recognition Sensor -G397- and without Driver Assistance Systems Front Camera -R242-..................4426 5.1.3 Overview - Interior Rearview Mirror with Automatic Dimming, with Rain/Light Recognition Sensor -G397- and Driver Assistance Systems Front Camera -R242-....................................4427 5.2 Interior Rearview Mirror, Removing and Installing................................................................................................................................................4428 5.2.1 Manual Dimming Interior Rearview Mirror, Removing and Installing, without Rain/Light Recognition Sensor -G397- and Driver Assistance Systems Front Camera -R242-...........................4428 5.2.2 Manual or Automatic Dimming Interior Rearview Mirror, Removing and Installing, with Rain/Light Recognition Sensor -G397- and without Driver Assistance Systems Front Camera -R242-.........4429 5.2.3 Automatic Dimming Interior Rearview Mirror, Removing and Installing, with Rain/Light Recognition Sensor -G397- and Driver Assistance Systems Front Camera -R242-...........................4429 5.3 Baseplate, Removing and Installing...............................................................................................................................................................4430 5.3.1 Manual or Automatic Dimming Interior Rearview Mirror Baseplate, Removing and Installing, without Rain/Light Recognition Sensor -G397- and Driver Assistance Systems Front Camera -R242-....4430 5.3.2 Manual Dimming Interior Rearview Mirror Baseplate, Removing and Installing, with Rain/Light Recognition Sensor -G397- and without Driver Assistance Systems Front Camera -R242-............4432 6 Special Tools..........................................................................................................................................................................................4434 69 – Passenger Protection, Airbags, Seat Belts...............................................................................................................................................................4435 1 Seat Belts.............................................................................................................................................................................................4435 1.1 Component Location Overview - Seat Belts and Attaching Points....................................................................................................................................4435 1.1.1 Component Location Overview - Seat Belts and Attaching Points, 2-Door......................................................................................................................4435 1.1.2 Component Location Overview - Seat Belts and Attaching Points, 4-Door......................................................................................................................4438 1.1.3 Component Location Overview - Seat Belts and Attaching Points, Wagon.......................................................................................................................4440 1.2 Overview - Front Three-Point Seat Belt...........................................................................................................................................................4442 1.2.1 Overview - Front Three-Point Seat Belt, 2-Door.............................................................................................................................................4442 1.2.2 Overview - Front Three-Point Seat Belt, 4-Door and Wagon...................................................................................................................................4444 1.2.3 Overview - Front Three-Point Seat Belt, with Belt End Fitting Tensioner....................................................................................................................4445 1.3 Overview - Rear Outer Three-Point Seat Belt......................................................................................................................................................4447 1.3.1 Overview - Three-Point Seat Belt, 2-Door without Belt Tensioner............................................................................................................................4447 1.3.2 Overview - Three-Point Seat Belt, 2-Door with Belt Tensioner...............................................................................................................................4448 1.3.3 Overview - Three-Point Seat Belt, 4-Door without Belt Tensioner............................................................................................................................4449 1.3.4 Overview - Three-Point Seat Belt, 4-Door with Belt Tensioner...............................................................................................................................4450 1.3.5 Overview - Three-Point Seat Belt, Wagon without Belt Tensioner.............................................................................................................................4451 1.3.6 Overview - Three-Point Seat Belt, Wagon with Belt Tensioner................................................................................................................................4452 1.4 Overview - Rear Center Three-Point Seat Belt.....................................................................................................................................................4453 1.5 Overview - Front Seat Belt Latch.................................................................................................................................................................4454 1.5.1 Overview - Front Seat Belt Latch, 2-Door...................................................................................................................................................4454 1.5.2 Overview - Front Seat Belt Latch, 4-Door and Wagon.........................................................................................................................................4455 1.6 Overview - Rear Seat Belt Latch..................................................................................................................................................................4456 1.7 Front Three-Point Seat Belt, Removing and Installing.............................................................................................................................................4457 1.7.1 Front Three-Point Seat Belt, Removing and Installing, 2-Door...............................................................................................................................4457 1.7.2 Front Three-Point Seat Belt, Removing and Installing, 4-Door and Wagon.....................................................................................................................4459 1.7.3 Front Three-Point Seat Belt, Removing and Installing, with Belt End Fitting Tensioner......................................................................................................4461 1.8 Rear Three-Point Seat Belt, Removing and Installing..............................................................................................................................................4464 1.8.1 Rear Three-Point Seat Belt, Removing and Installing, 2-Door without Belt Tensioner.........................................................................................................4464 1.8.2 Rear Three-Point Seat Belt, Removing and Installing, 2-Door with Belt Tensioner............................................................................................................4465 1.8.3 Rear Three-Point Seat Belt, Removing and Installing, 4-Door without Belt Tensioner.........................................................................................................4467 1.8.4 Rear Three-Point Seat Belt, Removing and Installing, 4-Door with Belt Tensioner............................................................................................................4467 1.8.5 Rear Three-Point Seat Belt, Removing and Installing, Wagon without Belt Tensioner..........................................................................................................4469 1.8.6 Rear Three-Point Seat Belt, Removing and Installing, Wagon with Belt Tensioner.............................................................................................................4470 1.8.7 Rear Three Point Seat Belt in Center Seating Position, Removing and Installing.............................................................................................................4471 1.9 Front Seat Belt Guide, Removing and Installing...................................................................................................................................................4472 1.9.1 Front Seat Belt Guide, Removing and Installing, 2-Door.....................................................................................................................................4472 1.9.2 Front Seat Belt Guide, Removing and Installing, 4-Door and Wagon...........................................................................................................................4473 1.10 Rear Seat Belt Guide, Removing and Installing...................................................................................................................................................4473 1.11 Front Belt End Fitting, Removing and Installing.................................................................................................................................................4474 1.11.1 Front Belt End Fitting, Removing and Installing, 2-Door...................................................................................................................................4474 1.11.2 Front Belt End Fitting, Removing and Installing, 4-Door and Wagon.........................................................................................................................4474 1.11.3 Front Belt End Fitting, Removing and Installing, with Belt End Fitting Tensioner..........................................................................................................4475 1.12 Rear Outer Belt End Fitting, Removing and Installing............................................................................................................................................4476 1.13 Seat Belt Height Adjuster, Removing and Installing..............................................................................................................................................4476 1.13.1 Seat Belt Height Adjuster, Removing and Installing, 2-Door................................................................................................................................4476 1.13.2 Seat Belt Height Adjuster, Removing and Installing, 4-Door and Wagon......................................................................................................................4478 1.14 Front Seat Belt Latch, Removing and Installing..................................................................................................................................................4479 1.14.1 Front Seat Belt Latch, Removing and Installing, 2-Door Vehicles...........................................................................................................................4479 1.14.2 Front Seat Belt Latch, Removing and Installing, 4-Door Vehicles and Wagon.................................................................................................................4480 1.15 Rear Seat Belt Latch, Removing and Installing...................................................................................................................................................4482 2 Child Seat Anchors.....................................................................................................................................................................................4483 2.1 Overview - Rear Child Seat Anchors...............................................................................................................................................................4483 2.2 LATCH Child Seat Anchor Guide, Removing and Installing...........................................................................................................................................4484 2.3 Top Tether Cover, Removing and Installing........................................................................................................................................................4484 3 Airbag System..........................................................................................................................................................................................4485 3.1 Component Location Overview - Airbag System......................................................................................................................................................4485 4 Airbag Control Module..................................................................................................................................................................................4487 4.1 Overview - Airbag Control Module.................................................................................................................................................................4487 4.2 Airbag Control Module -J234-, Removing and Installing............................................................................................................................................4487 5 Driver Side Airbag.....................................................................................................................................................................................4491 5.1 Overview - Driver Side Airbag....................................................................................................................................................................4491 5.2 Airbag Unit with Driver Airbag Igniter -N95-, Removing and Installing............................................................................................................................4492 5.3 Airbag Connector, Replacing......................................................................................................................................................................4496 6 Front Passenger Airbag.................................................................................................................................................................................4499 6.1 Overview - Front Passenger Airbag................................................................................................................................................................4499 6.2 Front Passenger Airbag Unit with Front Passenger Airbag Igniter 1 - N131-, Removing and Installing...............................................................................................4500 6.3 Front Passenger Airbag Deactivation Key Switch, Removing and Installing..........................................................................................................................4502 6.4 Front Passenger Airbag -Disabled- Indicator Lamp -K145-, Removing and Installing.................................................................................................................4503 7 Side Airbags...........................................................................................................................................................................................4504 7.1 Overview - Front Side Airbag.....................................................................................................................................................................4504 7.2 Overview - Rear Side Airbag......................................................................................................................................................................4505 7.3 Front Side Airbag with Driver Thorax Airbag Igniter -N199-/ Front Passenger Thorax Airbag Igniter -N200-, Removing and Installing................................................................4506 7.4 Rear Side Airbag with Driver/Passenger Side Rear Thorax Airbag Igniter -N201-/-N202-, Removing and Installing....................................................................................4507 8 Head Curtain Airbags...................................................................................................................................................................................4509 8.1 Overview - Head Curtain Airbag...................................................................................................................................................................4509 8.2 Head Curtain Airbag with Igniter, Removing and Installing........................................................................................................................................4510 8.2.1 Head Curtain Airbag with Igniter, Removing and Installing, 2-and 4-Door Vehicles...........................................................................................................4510 8.2.2 Head Curtain Airbag with Igniter, Removing and Installing, Wagon Vehicles..................................................................................................................4513 9 Knee Airbags...........................................................................................................................................................................................4518 9.1 Overview - Knee Airbag...........................................................................................................................................................................4518 9.2 Knee Airbag with Driver Knee Airbag Igniter -N295-, Removing and Installing......................................................................................................................4519 10 Airbag Crash Sensors..................................................................................................................................................................................4522 10.1 Component Location Overview - Airbag Crash Sensors..............................................................................................................................................4522 10.2 Front Airbag Crash Sensor -G190-, Removing and Installing.......................................................................................................................................4523 10.3 Driver Front Airbag Crash Sensor -G283-, Removing and Installing................................................................................................................................4527 10.4 Passenger Side Front Airbag Crash Sensor -G284-, Removing and Installing........................................................................................................................4530 10.5 Driver Side Airbag Crash Sensor -G179-/ Front Passenger Side Airbag Crash Sensor -G180-, Removing and Installing................................................................................4532 10.5.1 Driver/Front Passenger Side Airbag Crash Sensor -G179-/-G180-, Removing and Installing, Vehicles without Head Curtain Airbag..............................................................4532 10.5.2 Driver/Front Passenger Side Airbag Crash Sensor -G179-/-G180-, Removing and Installing, Only Chinese Market without Head Curtain Airbag...................................................4535 10.6 Driver Side Rear Side Airbag Crash Sensor -G256-/ Passenger Side Rear Side Airbag Crash Sensor-G257-, Removing and Installing...................................................................4540 11 Seat Position Sensor..................................................................................................................................................................................4543 11.1 Overview - Seat Position Sensor.................................................................................................................................................................4543 11.2 Seat Position Sensor, Removing and Installing...................................................................................................................................................4544 12 Belt Fastening Detection..............................................................................................................................................................................4547 12.1 Front Passenger Occupant Detection Sensor -G128-, Removing and Installing.......................................................................................................................4547 13 Passenger Occupant Detection System...................................................................................................................................................................4550 13.1 Overview - Passenger Occupant Detection System..................................................................................................................................................4550 13.2 Passenger Occupant Detection System Pressure Sensor, Removing and Installing....................................................................................................................4552 13.3 Passenger Occupant Detection System Control Module -J706-, Removing and Installing..............................................................................................................4558 13.4 Passenger Occupant Detection System Control Module -J706- Bracket, Removing and Installing......................................................................................................4560 13.5 Required Importer Notification..................................................................................................................................................................4561 14 Special Tools.........................................................................................................................................................................................4563 70 – Interior Trim...........................................................................................................................................................................................4564 1 Front Door Trim Panels.................................................................................................................................................................................4564 1.1 Overview - Front Door Trim Panel.................................................................................................................................................................4564 1.2 Front Door Trim Panel, Removing and Installing...................................................................................................................................................4565 1.3 Trim Molding, Removing and Installing............................................................................................................................................................4569 1.4 Mirror Cover Trim, Removing and Installing.......................................................................................................................................................4571 2 Rear Door Trim Panels..................................................................................................................................................................................4573 2.1 Overview - Rear Door Trim Panel..................................................................................................................................................................4573 2.2 Rear Door Trim Panel, Removing and Installing....................................................................................................................................................4574 2.3 Trim Molding, Removing and Installing............................................................................................................................................................4577 2.4 Interior Door Mechanism, Removing and Installing.................................................................................................................................................4579 3 Instrument Panel.......................................................................................................................................................................................4581 3.1 Overview - Instrument Panel......................................................................................................................................................................4581 3.2 Instrument Panel Side Cover, Removing and Installing.............................................................................................................................................4582 3.3 Instrument Panel Decorative Trim, Removing and Installing........................................................................................................................................4582 3.4 Light Switch Trim, Removing and Installing.......................................................................................................................................................4583 3.5 Instrument Cluster Trim, Removing and Installing.................................................................................................................................................4583 3.6 Instrument Panel, Removing and Installing........................................................................................................................................................4584 3.7 Instrument Panel Vent, Removing and Installing...................................................................................................................................................4592 3.8 Side Defroster Vent, Removing and Installing.....................................................................................................................................................4595 4 Instrument Panel Central Tube..........................................................................................................................................................................4597 4.1 Overview - Instrument Panel Central Tube.........................................................................................................................................................4597 4.2 Overview - Driver Side Impact Absorber...........................................................................................................................................................4599 4.3 Crash Bolster, Removing and Installing...........................................................................................................................................................4600 4.4 Instrument Panel Central Tube, Removing and Installing...........................................................................................................................................4601 4.5 Driver Side Impact Absorber, Removing and Installing.............................................................................................................................................4605 4.6 Front Passenger Side Impact Absorber, Removing and Installing....................................................................................................................................4606 5 Passenger Compartment Trim.............................................................................................................................................................................4608 5.1 Component Location Overview - Passenger Compartment Trim.........................................................................................................................................4608 5.1.1 Component Location Overview - Passenger Compartment Trim, 2-Door...........................................................................................................................4608 5.1.2 Component Location Overview - Passenger Compartment Trim, 4-Door...........................................................................................................................4610 5.1.3 Component Location Overview - Passenger Compartment Trim, Wagon............................................................................................................................4611 5.2 Overview - Sill Panel Strip......................................................................................................................................................................4612 5.3 Overview - A-Pillar Trim Panel...................................................................................................................................................................4612 5.4 Overview - B-Pillar Trim Panel...................................................................................................................................................................4614 5.5 Overview - C-Pillar Trim Panel...................................................................................................................................................................4616 5.5.1 Overview - C-Pillar Trim Panel, Sedan......................................................................................................................................................4616 5.5.2 Overview - C-Pillar Trim Panel, Wagon......................................................................................................................................................4618 5.6 Overview - D-Pillar Trim Panel...................................................................................................................................................................4619 5.7 Overview - Side Trim Panel.......................................................................................................................................................................4620 5.8 Overview - Wheel Housing Trim Panel..............................................................................................................................................................4620 5.8.1 Overview - Wheel Housing Trim Panel, Sedan.................................................................................................................................................4620 5.8.2 Overview - Wheel Housing Trim Panel, Wagon.................................................................................................................................................4621 5.9 Overview - Foot Rest and Carpet..................................................................................................................................................................4623 5.9.1 Overview - Foot Rest and Carpet............................................................................................................................................................4623 5.9.2 Overview - Foot Rest and Carpet, RHD Vehicles..............................................................................................................................................4624 5.10 Sill Panel Strip, Removing and Installing.......................................................................................................................................................4624 5.10.1 Sill Panel Strip, Removing and Installing, 2-Door.........................................................................................................................................4624 5.10.2 Sill Panel Strip, Removing and Installing, 4-Door.........................................................................................................................................4625 5.11 A-Pillar Gap Cover, Removing and Installing.....................................................................................................................................................4626 5.12 A-Pillar Trim Panel, Removing and Installing....................................................................................................................................................4627 5.13 B-Pillar Trim Panel, Removing and Installing....................................................................................................................................................4632 5.13.1 B-Pillar Trim Panel, Removing and Installing, 4-Door and Wagon............................................................................................................................4632 5.13.2 B-Pillar Trim Panel, Removing and Installing, 2-Door......................................................................................................................................4635 5.14 C-Pillar Trim Panel, Removing and Installing....................................................................................................................................................4637 5.14.1 C-Pillar-Trim Panel, Removing and Installing, Sedan.......................................................................................................................................4637 5.14.2 C-Pillar-Trim Panel, Removing and Installing, Wagon.......................................................................................................................................4638 5.15 D-Pillar Trim Panel, Removing and Installing....................................................................................................................................................4639 5.16 Side Trim Panel, Removing and Installing........................................................................................................................................................4640 5.17 Wheel Housing Trim Panel, Removing and Installing...............................................................................................................................................4643 5.17.1 Wheel Housing Trim Panel, Removing and Installing, Sedan..................................................................................................................................4643 5.17.2 Wheel Housing Trim Panel, Removing and Installing, Wagon..................................................................................................................................4645 5.18 Foot Rest, Removing and Installing..............................................................................................................................................................4647 5.18.1 Foot Rest, Removing and Installing........................................................................................................................................................4647 5.18.2 Foot Rest, Removing and Installing, RHD Vehicles..........................................................................................................................................4648 5.19 Carpet, Removing and Installing.................................................................................................................................................................4649 6 Luggage Compartment Trim Panels........................................................................................................................................................................4650 6.1 Component Location Overview - Luggage Compartment Trim Panels....................................................................................................................................4650 6.1.1 Component Location Overview - Luggage Compartment Trim Panels, Sedan.......................................................................................................................4650 6.1.2 Component Location Overview - Luggage Compartment Trim Panels, Wagon.......................................................................................................................4652 6.2 Overview - Rear Shelf Compartment................................................................................................................................................................4653 6.3 Overview - Luggage Compartment Side Trim Panel...................................................................................................................................................4654 6.3.1 Overview - Luggage Compartment Side Trim Panel, Sedan......................................................................................................................................4654 6.3.2 Overview - Luggage Compartment Side Trim Panel, Wagon......................................................................................................................................4655 6.4 Overview - Luggage Compartment Floor.............................................................................................................................................................4656 6.4.1 Overview - Luggage Compartment Floor, Sedan................................................................................................................................................4656 6.4.2 Overview - Luggage Compartment Floor, Golf “GTE”...........................................................................................................................................4657 6.4.3 Overview - Luggage Compartment Floor, Wagon................................................................................................................................................4658 6.5 Overview - Upper Rear Lid Trim Panel.............................................................................................................................................................4659 6.6 Overview - Lower Rear Lid Trim Panel.............................................................................................................................................................4660 6.7 Luggage Compartment Cover, Removing and Installing...............................................................................................................................................4660 6.8 Lock Carrier Trim Panel, Removing and Installing.................................................................................................................................................4661 6.9 Rear Shelf Compartment, Removing and Installing..................................................................................................................................................4662 6.10 Tie Down, Removing and Installing...............................................................................................................................................................4664 6.11 Luggage Compartment Floor Covering Bracket, Removing and Installing.............................................................................................................................4664 6.11.1 Luggage Compartment Floor Covering Bracket, Removing and Installing, Sedan................................................................................................................4664 6.11.2 Luggage Compartment Floor Covering Bracket, Removing and Installing, Wagon................................................................................................................4665 6.12 Luggage Compartment Side Trim Panel, Removing and Installing....................................................................................................................................4666 6.12.1 Luggage Compartment Side Trim Panel, Removing and Installing, Sedan.......................................................................................................................4666 6.12.2 Luggage Compartment Side Trim Panel, Removing and Installing, Wagon.......................................................................................................................4667 6.13 Upper Rear Lid Trim Panel, Removing and Installing..............................................................................................................................................4670 6.14 Lower Rear Lid Trim Panel, Removing and Installing..............................................................................................................................................4672 7 Roof Trim Panels.......................................................................................................................................................................................4674 7.1 Overview - Headliner.............................................................................................................................................................................4674 7.1.1 Overview - Headliner, Sedan................................................................................................................................................................4674 7.1.2 Overview - Headliner, Wagon................................................................................................................................................................4675 7.2 Roof End Strip, Removing and Installing..........................................................................................................................................................4676 7.3 Headliner, Removing and Installing...............................................................................................................................................................4676 7.3.1 Headliner, Removing and Installing, Sedan..................................................................................................................................................4676 7.3.2 Headliner, Removing and Installing, Wagon..................................................................................................................................................4678 7.4 Roof Reinforcement, Attaching to Body............................................................................................................................................................4680 7.4.1 Roof Reinforcement, Attaching to Body, Sedan and Wagon without Sunroof.....................................................................................................................4680 7.4.2 Roof Reinforcement, Attaching to Body, Wagon with Sunroof..................................................................................................................................4682 8 Special Tools..........................................................................................................................................................................................4684 72 – Seat Frames.............................................................................................................................................................................................4687 1 Overview - Seat Versions...............................................................................................................................................................................4687 1.1 Component Location Overview - Seat Versions......................................................................................................................................................4687 1.2 Front Seat, Mounting on Fixture for Seat Repair..................................................................................................................................................4688 2 Front Seats............................................................................................................................................................................................4690 2.1 Component Location Overview - Electric and Electronic Components.................................................................................................................................4691 2.1.1 Component Locations Overview - Electric and Electronic Components, Standard Seat ergo Active Seat..........................................................................................4691 2.1.2 Component Locations Overview - Electric and Electronic Components, Power Seat..............................................................................................................4693 2.2 Overview - Front Seat............................................................................................................................................................................4695 2.2.1 Overview - Front Seat, Standard Seat ergo Active Seat......................................................................................................................................4695 2.2.2 Overview - Front Seat, Power Seat..........................................................................................................................................................4697 2.3 Overview - Backrest Release and Entry Assistance.................................................................................................................................................4699 2.4 Overview - Front Backrest........................................................................................................................................................................4700 2.5 Overview - Seat Pan..............................................................................................................................................................................4704 2.6 Overview - Fire Extinguisher.....................................................................................................................................................................4714 2.7 Front Seat, Removing and Installing..............................................................................................................................................................4714 2.8 Front Seat, Removing with Faulty Driver/Front Passenger Seat Forward/Back Adjustment Motor -V28-/-V31-...........................................................................................4719 2.9 Airbag Adapter, Connecting and Disconnecting.....................................................................................................................................................4723 2.10 Tunnel-Side Seat Trim, Removing and Installing..................................................................................................................................................4724 2.11 Sill-Side Seat Trim, Removing and Installing....................................................................................................................................................4725 2.11.1 Sill-Side Seat Trim, Removing and Installing, ergo Active Seat............................................................................................................................4725 2.11.2 Sill-Side Seat Trim, Removing and Installing, Standard Seat...............................................................................................................................4727 2.11.3 Door Sill Side Seat Trim, Removing and Installing, Power Seat.............................................................................................................................4729 2.12 Seat Trim Bracket, Removing and Installing......................................................................................................................................................4730 2.12.1 Seat Trim Bracket, Removing and Installing, ergo Active Seat..............................................................................................................................4730 2.12.2 Seat Trim Bracket, Removing and Installing, Standard Seat.................................................................................................................................4730 2.12.3 Seat Trim Bracket, Removing and Installing, Power Seat....................................................................................................................................4731 2.13 Front Backrest, Removing and Installing.........................................................................................................................................................4732 2.14 Seat Depth Adjuster, Removing and Installing....................................................................................................................................................4733 2.15 Seat Angle Adjuster, Removing and Installing....................................................................................................................................................4737 2.15.1 Seat Angle Adjuster, Removing and Installing, Standard Seat, ergo Active Seat.............................................................................................................4737 2.15.2 Seat Angle Adjuster, Removing and Installing, Power Seat..................................................................................................................................4738 2.16 Seat Height Adjuster Handle, Removing and Installing............................................................................................................................................4739 2.17 Seat Height Adjuster, Removing and Installing...................................................................................................................................................4740 2.17.1 Seat Height Adjuster, Removing and Installing, Standard Seat, ergo Active Seat............................................................................................................4740 2.17.2 Seat Height Adjuster, Removing and Installing, Power Seat.................................................................................................................................4742 2.18 Lower Seat Frame with Driver/Front Passenger Seat Forward/Back Adjustment Motor -V28-/-V31-, Removing and Installing............................................................................4744 2.19 Backrest Adjuster, Removing and Installing......................................................................................................................................................4745 2.19.1 Backrest Adjuster, Removing and Installing, Standard Seat without Pass-Through, ergo Active Seat..........................................................................................4745 2.19.2 Backrest Adjuster, Removing and Installing, Standard Seat with Pass-Through...............................................................................................................4745 2.19.3 Backrest Adjuster, Removing and Installing, Power Seat....................................................................................................................................4746 2.20 Lumbar Support Adjuster, Removing and Installing................................................................................................................................................4746 2.21 Headrest, Removing and Installing...............................................................................................................................................................4747 2.22 Headrest Guide, Removing and Installing.........................................................................................................................................................4748 2.23 Backrest Release Trim, Removing and Installing..................................................................................................................................................4749 2.24 Backrest Release, Removing and Installing.......................................................................................................................................................4750 2.25 Connecting Cable, Removing and Installing.......................................................................................................................................................4750 2.26 Backrest Release Mount, Removing and Installing.................................................................................................................................................4751 2.27 Backrest Release Cable, Removing and Installing.................................................................................................................................................4752 2.28 Backrest Release Cable, Adjusting...............................................................................................................................................................4753 2.29 Entry Assistance Release Cable A, Removing and Installing.......................................................................................................................................4755 2.30 Entry Assistance Release Cable A, Adjusting.....................................................................................................................................................4756 2.31 Entry Assistance Cable B, Removing and Installing...............................................................................................................................................4757 2.32 Gliding Piece, Removing and Installing..........................................................................................................................................................4758 2.33 Storage Compartment, Removing and Installing....................................................................................................................................................4759 2.34 Driver/Front Passenger Seat Lumbar Support Adjustment Switch -E176-/-E177-, Removing and Installing.............................................................................................4760 2.35 Lumbar Support Adjustment Motors -V125-/-V126-/-V129-/-V130-, Removing and Installing...........................................................................................................4760 2.36 Driver/Front Passenger Seat Adjustment Control Head -E470-/-E471-, Removing and Installing......................................................................................................4761 2.37 Massage Function Control Module -J740-, Removing and Installing.................................................................................................................................4762 3 Rear Seats.............................................................................................................................................................................................4763 3.1 Overview - Seat Bench/Single Seat................................................................................................................................................................4763 3.2 Overview - Rear Seat Backrest....................................................................................................................................................................4765 3.3 Overview - Locking Mechanism.....................................................................................................................................................................4767 3.4 Overview - Center Armrest........................................................................................................................................................................4768 3.5 Overview - Side Cushion..........................................................................................................................................................................4769 3.6 Overview - Backrest Remote Release...............................................................................................................................................................4769 3.7 Seat Bench/Single Seat, Removing and Installing..................................................................................................................................................4770 3.8 Rear Seat Backrest, Removing and Installing......................................................................................................................................................4772 3.9 Locking Mechanism Trim, Removing and Installing..................................................................................................................................................4773 3.10 Rear Seat Backrest Locking Mechanism, Removing and Installing...................................................................................................................................4774 3.11 Pass-Through Cover Frame, Removing and Installing...............................................................................................................................................4774 3.12 Pass-Through Cover, Removing and Installing.....................................................................................................................................................4775 3.13 Center Armrest, Removing and Installing.........................................................................................................................................................4776 3.14 Headrest, Removing and Installing...............................................................................................................................................................4777 3.15 Headrest Guide, Removing and Installing.........................................................................................................................................................4777 3.16 Side Cushion, Removing and Installing...........................................................................................................................................................4778 3.17 Release Cable for Backrest Remote Release, Disconnecting and Connecting.........................................................................................................................4780 3.18 Actuator for Backrest Remote Release, Removing and Installing...................................................................................................................................4781 3.19 Backrest Remote Release Cable, Removing and Installing..........................................................................................................................................4782 4 Special Tools..........................................................................................................................................................................................4785 74 – Seat Upholstery, Covers.................................................................................................................................................................................4788 1 Front Seat Covers and Cushions.........................................................................................................................................................................4788 1.1 Overview - Seat Pan Cover and Cushion............................................................................................................................................................4788 1.1.1 Overview - Seat Pan Cover and Cushion......................................................................................................................................................4788 1.1.2 Overview - Seat Pat Cover and Cushion, Seat Depth Adjuster.................................................................................................................................4790 1.2 Overview - Backrest Cover and Cushion............................................................................................................................................................4791 1.3 Overview - Seat Heating Element..................................................................................................................................................................4792 1.4 Seat Pan Cover and Cushion, Removing and Installing..............................................................................................................................................4792 1.5 Backrest Cover and Cushion, Removing and Installing..............................................................................................................................................4795 1.6 Seat Pan Cover and Cushion, Separating...........................................................................................................................................................4797 1.7 Backrest Cover and Cushion, Separating...........................................................................................................................................................4799 1.8 Driver and Front Passenger Seat Heating Element -Z6-/-Z8-, Removing and Installing...............................................................................................................4804 1.8.1 Driver/Front Passenger Seat Heating Element -Z6-/-Z8-, Removing and Installing, Vehicles without Passenger Occupant Detection System.......................................................4804 1.8.2 Front Passenger Seat Heating Element - Z8-, Removing and Installing, Vehicles with Passenger Occupant Detection System.....................................................................4805 1.9 Driver and Front Passenger Backrest Heating Element -Z7-/-Z9-, Removing and Installing...........................................................................................................4805 2 Rear Seat Covers and Cushions..........................................................................................................................................................................4807 2.1 Overview - Bench Seat Cover and Cushion..........................................................................................................................................................4807 2.2 Overview - Rear Seat Backrest Cover and Cushion..................................................................................................................................................4808 2.3 Bench Seat Cover and Cushion, Removing and Installing............................................................................................................................................4809 2.4 Rear Seat Backrest Cover and Cushion, Removing and Installing....................................................................................................................................4809 2.5 Center Cushion, Removing and Installing, Backrest with Pass-Through..............................................................................................................................4811 2.6 Bench Seat Cover and Cushion, Separating.........................................................................................................................................................4812 2.7 Rear Seat Backrest Cover and Cushion, Separating.................................................................................................................................................4812 3 Special Tools..........................................................................................................................................................................................4814 4 Revision History.......................................................................................................................................................................................4815 09-Electrical Equipment.pdf (p.4819-5398)............................................................................................................................................................................4819 09-01 Electrical Equipment General Information...................................................................................................................................................................4819 27 – Battery, Starter, Generator, Cruise Control.............................................................................................................................................................4825 1 Battery................................................................................................................................................................................................4825 1.1 Battery General Information......................................................................................................................................................................4825 1.2 Types of Batteries...............................................................................................................................................................................4825 1.2.1 Battery with Visual Indicator, Standard....................................................................................................................................................4826 1.2.2 Battery with Visual Indicator, Enhanced....................................................................................................................................................4826 1.2.3 AGM Battery................................................................................................................................................................................4827 1.3 Warnings and Safety Precautions..................................................................................................................................................................4827 1.3.1 Battery Safety Precautions.................................................................................................................................................................4827 1.3.3 Working on Airbag System...................................................................................................................................................................4829 1.4 Battery Post/Terminal............................................................................................................................................................................4829 2 Battery, Checking......................................................................................................................................................................................4830 2.1 General Information..............................................................................................................................................................................4830 2.2 Batteries, Checking..............................................................................................................................................................................4830 2.2.1 Battery with Visual Indicator, Checking....................................................................................................................................................4830 2.2.2 AGM Battery, Checking......................................................................................................................................................................4831 2.3 Visual Inspection................................................................................................................................................................................4831 2.4 Visual Display in Battery Cover, Checking........................................................................................................................................................4832 2.4.1 3-Color Visual Indicator, Checking.........................................................................................................................................................4832 2.4.2 “2 Color” Visual Indicator, Checking.......................................................................................................................................................4833 2.5 Battery Tester -VAS6161-.........................................................................................................................................................................4834 2.5.2 Battery Test, Performing using Battery Tester -VAS6161-....................................................................................................................................4835 2.5.3 Warranty Test, Performing..................................................................................................................................................................4836 2.5.4 Maintenance Test, Performing...............................................................................................................................................................4836 2.5.5 Service Test, Performing...................................................................................................................................................................4837 2.5.7 Evaluating Test Results....................................................................................................................................................................4838 2.6 Midtronics Battery Tester -MCR340VKT-............................................................................................................................................................4839 2.6.1 General Information........................................................................................................................................................................4839 2.6.2 Battery, Testing using Midtronics Battery Tester -MCR340VKT-...............................................................................................................................4840 2.6.3 Evaluating Test Results....................................................................................................................................................................4841 2.6.4 Midtronics Battery Tester -MCR340VKT-, Troubleshooting.....................................................................................................................................4842 2.7 Current Draw Test................................................................................................................................................................................4843 3 Battery, Charging......................................................................................................................................................................................4845 3.1 Battery Charger -VAS5095A-.......................................................................................................................................................................4845 3.1.1 Battery Charger -VAS5095A- Device Description..............................................................................................................................................4845 3.1.2 Battery, Charging with Battery Charger -VAS5095A-..........................................................................................................................................4846 3.1.3 Severely Discharged Battery, Charging with Battery Charger -VAS5095A-......................................................................................................................4847 3.1.4 Support Mode with Battery Charger -VAS5095A-...............................................................................................................................................4848 3.1.5 Battery Charger -VAS5095A- Maintenance Charging............................................................................................................................................4850 3.2 Battery Charger -VAS5900-........................................................................................................................................................................4851 3.2.1 Battery Charger -VAS5900- Device Description...............................................................................................................................................4851 3.2.2 Battery, Charging with Battery Charger -VAS5900-...........................................................................................................................................4852 3.2.3 Service Charging with Battery Charger -VAS5900-............................................................................................................................................4853 3.2.4 Severely Discharged Batteries, Charging with Battery Charger -VAS5900-.....................................................................................................................4856 3.2.5 Support Mode with Battery Charger -VAS5900-................................................................................................................................................4858 3.2.6 Battery Charger -VAS5900- Maintenance Charging.............................................................................................................................................4860 3.3 Battery Charger -VAS5903-........................................................................................................................................................................4861 3.3.1 Battery Charger -VAS5903- Device Description...............................................................................................................................................4861 3.3.2 Battery, Charging with Battery Charger -VAS5903-...........................................................................................................................................4862 3.3.3 Refresh Charging with Battery Charger -VAS5903-............................................................................................................................................4864 3.3.4 Severely Discharged Battery, Charging with Battery Charger -VAS5903-.......................................................................................................................4867 3.3.5 Support Mode with Battery Charger -VAS5903-................................................................................................................................................4869 3.3.6 Battery Charger -VAS5903- Maintenance Charging.............................................................................................................................................4871 3.4 Battery Charger -VAS5906-........................................................................................................................................................................4873 3.4.2 Battery, Charging with Battery Charger -VAS5906-...........................................................................................................................................4873 3.5 Battery Tester Charger Kit -GRX3000VAS-..........................................................................................................................................................4876 3.5.1 Battery Tester Charger Kit -GRX3000VAS- General Description................................................................................................................................4876 3.5.2 Battery, Charging..........................................................................................................................................................................4877 3.5.3 Battery Tester Charger Kit -GRX3000VAS- Troubleshooting....................................................................................................................................4879 3.6 Solar Battery Maintainer -VAS6102A-..............................................................................................................................................................4880 3.7 Severely Discharged Batteries....................................................................................................................................................................4880 4 Cruise Control System..................................................................................................................................................................................4882 4.1 Cruise Control System, Activating and Deactivating...............................................................................................................................................4882 5 Special Tools..........................................................................................................................................................................................4883 92 – Wiper/Washer Systems....................................................................................................................................................................................4884 1 Washer Fluid Line Hose Connections.....................................................................................................................................................................4884 1.1 Windshield and Rear Window Washer System.........................................................................................................................................................4884 1.2 Headlamp Washer System...........................................................................................................................................................................4885 2 Hoses, Repairing.......................................................................................................................................................................................4886 2.1 General Information..............................................................................................................................................................................4886 2.2 Smooth Tube, Repairing...........................................................................................................................................................................4886 2.3 Corrugated Tube, Repairing.......................................................................................................................................................................4886 3 Joint-Free Wiper Blade Characteristics.................................................................................................................................................................4888 4 Special Tools..........................................................................................................................................................................................4889 94 – Exterior Lights, Switches...............................................................................................................................................................................4890 1 HID Headlamp Usage and Safety Precautions..............................................................................................................................................................4890 96 – Interior Lights, Switches...............................................................................................................................................................................4893 1 12 V Socket ...........................................................................................................................................................................................4893 1.1 12 V Socket , Removing and Installing............................................................................................................................................................4893 1.2 Socket Illumination Bulb -L42-, Removing and Installing..........................................................................................................................................4893 2 Cigarette Lighter -U1-................................................................................................................................................................................4894 2.1 General Information..............................................................................................................................................................................4894 2.2 Overview - Cigarette Lighter -U1-................................................................................................................................................................4895 2.3 Cigarette Lighter Socket, Removing and Installing................................................................................................................................................4895 2.4 Cigarette Lighter Illumination Bulb -L28-, Removing and Installing...............................................................................................................................4898 3 Special Tools..........................................................................................................................................................................................4900 97 – Wiring..................................................................................................................................................................................................4901 1 Vehicle Diagnosis, Testing and Information Systems.....................................................................................................................................................4901 1.1 Vehicle Diagnostic Tester, Connecting............................................................................................................................................................4901 1.2 Vehicle Diagnostic Tester, Connecting, Golf MY 1998 through 2003.................................................................................................................................4902 2 Wiring Harness and Connector Repairs...................................................................................................................................................................4903 2.1 Vehicle Electrical System, General Repair Information............................................................................................................................................4903 2.2 Wiring Harness Repair Set........................................................................................................................................................................4906 2.2.1 Wiring Harness Repair Set -VAS1978-........................................................................................................................................................4906 2.2.2 Upgrade Kit For VAS1978 -VAS1978/50-.......................................................................................................................................................4906 2.2.3 Wiring Harness Repair Set -VAS1978A-.......................................................................................................................................................4907 2.2.4 Release Tool Set -VAS1978/35-..............................................................................................................................................................4907 2.3 Tool Descriptions................................................................................................................................................................................4908 2.3.1 Crimping Pliers with Insert................................................................................................................................................................4908 2.3.2 Contact Release Tools......................................................................................................................................................................4909 2.3.3 Single Wire Seal Assembly Tools............................................................................................................................................................4909 2.3.4 Wiring Harness Repair Set - Wire Strippers -VAS1978/3-.....................................................................................................................................4909 2.3.6 Crimping Pliers - .35-2.5mm -VAS1978/1A-...................................................................................................................................................4911 2.4 Wiring Harnesses, Repairing......................................................................................................................................................................4912 2.4.1 Airbag and Belt Tensioner Wire Repair Information..........................................................................................................................................4912 2.4.2 CAN Bus Wires, Repairing...................................................................................................................................................................4915 2.4.3 Antenna Wires, Replacing...................................................................................................................................................................4915 2.4.4 Wires with Cross Section up to 0.35 mm 2, Repairing........................................................................................................................................4916 2.4.5 Wire Break with Single Repair Point........................................................................................................................................................4919 2.4.6 Wire Break with Dual Repair Point..........................................................................................................................................................4920 2.5 Fiber-Optic Cables, Repairing....................................................................................................................................................................4922 2.5.1 Fiber-Optic Cable, Assembling..............................................................................................................................................................4922 2.5.2 Fiber-Optic Cable, Disconnecting from Wiring Harness Connector.............................................................................................................................4927 2.6 Antenna Wires, Repairing.........................................................................................................................................................................4928 2.6.1 Aerial Cable Repair Set -VAS6720-..........................................................................................................................................................4928 2.7 Contact Housings and Connectors, Repairing.......................................................................................................................................................4939 2.7.1 Contact Housings and Connectors, Repair Information........................................................................................................................................4939 2.7.2 Contacts in Contact Housing, Repairing.....................................................................................................................................................4939 2.7.3 Single Wire Seals, Installing..............................................................................................................................................................4941 2.7.4 Contact Housings, Repairing Wire Terminals.................................................................................................................................................4942 2.8 Contact Housings, Releasing and Disassembling....................................................................................................................................................4943 2.8.1 Releasing and Disassembly Contact Housings, General Information............................................................................................................................4943 2.8.2 Secondary Lock.............................................................................................................................................................................4943 2.8.3 Primary Lock...............................................................................................................................................................................4944 2.8.4 Round Connector Systems....................................................................................................................................................................4945 2.8.5 Flat Connector Systems.....................................................................................................................................................................4945 2.8.6 Special Connector Systems..................................................................................................................................................................4947 3 Contact Surface Cleaning Set -VAS6410-................................................................................................................................................................4949 3.1 Contact Surface Cleaning Set -VAS6410-, Using....................................................................................................................................................4949 3.1.1 Wiring Eyelets, Repairing..................................................................................................................................................................4949 3.1.2 Threaded Connections, Repairing............................................................................................................................................................4951 3.1.3 Battery Terminal Clamp and Battery Terminal, Cleaning......................................................................................................................................4952 3.1.4 Protecting.................................................................................................................................................................................4954 4 Heated Oxygen Sensor, Replacing........................................................................................................................................................................4955 4.1 4-Pin Heated Oxygen Sensor (HO2S), Removing and Installing.......................................................................................................................................4955 4.2 6-Pin Universal Oxygen Sensor, Removing and Installing...........................................................................................................................................4956 4.3 Oxygen Sensor Unit Protective Pipes..............................................................................................................................................................4956 5 Special Tools..........................................................................................................................................................................................4958 6 Revision History.......................................................................................................................................................................................4960 09-02 Electrical Equipment.......................................................................................................................................................................................4964 00 – General, Technical Data.................................................................................................................................................................................4972 1 Safety Precautions.....................................................................................................................................................................................4972 1.1 High Voltage Vehicles Safety Precautions.........................................................................................................................................................4972 1.2 Safety Precautions, Working Near High Voltage Components.........................................................................................................................................4972 1.3 Start/Stop System Safety Precautions.............................................................................................................................................................4973 1.4 Road Test with Testing Equipment Safety Precautions..............................................................................................................................................4973 1.5 HID Headlamp Usage and Safety Precautions........................................................................................................................................................4973 2 Repair Information.....................................................................................................................................................................................4976 2.1 Contact Corrosion................................................................................................................................................................................4976 2.2 Wire Routing and Securing........................................................................................................................................................................4976 3 Battery................................................................................................................................................................................................4977 3.1 Battery General Information......................................................................................................................................................................4977 3.2 Battery Types....................................................................................................................................................................................4977 27 – Battery, Starter, Generator, Cruise Control.............................................................................................................................................................4978 1 Battery................................................................................................................................................................................................4978 1.1 Overview - Battery...............................................................................................................................................................................4978 1.1.1 Overview - Battery.........................................................................................................................................................................4978 1.1.2 Overview - Battery, Vehicles with High Voltage System......................................................................................................................................4980 1.2 Battery, Removing and Installing.................................................................................................................................................................4981 1.2.1 Battery, Removing and Installing...........................................................................................................................................................4981 1.2.2 Battery, Removing and Installing, Vehicles with High Voltage System........................................................................................................................4983 1.3 Battery, Disconnecting and Connecting............................................................................................................................................................4987 1.3.1 Battery, Disconnecting and Connecting......................................................................................................................................................4987 1.3.2 Battery, Disconnecting and Connecting, High Voltage System.................................................................................................................................4988 1.4 Battery Tray, Removing and Installing............................................................................................................................................................4990 1.5 Battery, Checking................................................................................................................................................................................4991 1.6 Battery, Charging................................................................................................................................................................................4991 1.7 Ground Cable with Battery Monitoring Control Module -J367-, Removing and Installing..............................................................................................................4991 1.7.1 Ground Cable with Battery Monitoring Control Module -J367-, Removing and Installing........................................................................................................4991 1.7.2 Ground Cable with Battery Monitoring Control Module -J367-, Removing and Installing, Vehicles with High Voltage System.....................................................................4992 1.8 Battery Monitoring Control Module -J367-, Adapting...............................................................................................................................................4994 2 Generator..............................................................................................................................................................................................4995 2.1 Overview - Generator.............................................................................................................................................................................4995 2.1.1 Overview - Generator without Bushings......................................................................................................................................................4995 2.1.2 Overview - Generator with Bushings.........................................................................................................................................................4996 2.2 Generator, Removing and Installing...............................................................................................................................................................4996 2.2.1 Generator, Removing and Installing, Vehicles with 1.2L TSI-Engine, 1.4L TSI-Engine and 1.4L TSI-Natural Gas Engine.........................................................................4996 2.2.2 Generator, Removing and Installing.........................................................................................................................................................4998 2.2.3 Generator, Removing and Installing, Vehicles with TDI Engine...............................................................................................................................5000 2.2.4 Generator, Removing and Installing, GTD....................................................................................................................................................5001 2.3 Generator, Checking..............................................................................................................................................................................5003 2.4 Ribbed Belt Pulley, Removing and Installing......................................................................................................................................................5004 2.4.1 Ribbed Belt Pulley without Freewheel Hub, Removing and Installing..........................................................................................................................5004 2.4.2 Ribbed Belt Pulley with Freewheel Hub, Removing and Installing, Bosch......................................................................................................................5004 2.4.3 Ribbed Belt Pulley with Freewheel Hub, Removing and Installing, Valeo......................................................................................................................5006 2.4.4 Decoupling Belt Pulley with Freewheel, Removing and Installing.............................................................................................................................5007 2.5 Voltage Regulator, Removing and Installing.......................................................................................................................................................5009 2.5.1 Voltage Regulator, Removing and Installing, Bosch..........................................................................................................................................5009 2.5.2 Voltage Regulator, Removing and Installing, Valeo..........................................................................................................................................5010 3 Starter................................................................................................................................................................................................5012 3.1 Overview - Starter...............................................................................................................................................................................5012 3.1.1 Overview - Starter, Vehicles with Manual Transmission......................................................................................................................................5012 3.1.2 Overview - Starter, Vehicles with DSG® Transmission DQ200–7F...............................................................................................................................5013 3.1.3 Overview - Starter, Vehicles with DSG® Transmission DQ250-6F...............................................................................................................................5014 3.2 Starter, Removing and Installing.................................................................................................................................................................5014 3.2.1 Starter, Removing and Installing, Vehicles with Manual Transmission........................................................................................................................5014 3.2.2 Starter, Removing and Installing, Vehicles with DSG Transmission DQ200–7F..................................................................................................................5016 3.2.3 Starter, Removing and Installing, Vehicles with DSG Transmission...........................................................................................................................5017 4 Cruise Control System..................................................................................................................................................................................5019 5 Start/Stop System......................................................................................................................................................................................5020 5.1 General Description for Start/Stop System........................................................................................................................................................5020 5.2 Component Location Overview - Start/Stop System..................................................................................................................................................5020 6 Adaptive Cruise Control................................................................................................................................................................................5021 6.1 Component Location Overview - Adaptive Cruise Control (ACC)......................................................................................................................................5021 6.1.1 Component Location Overview- Adaptive Cruise Control (ACC), Version 1......................................................................................................................5021 6.1.2 Component Location Overview- Adaptive Cruise Control (ACC), Version 2......................................................................................................................5023 6.2 Control Module for Adaptive Cruise Control, Removing and Installing..............................................................................................................................5024 6.2.1 Control Module for Adaptive Cruise Control, Removing and Installing, Version 1.............................................................................................................5024 6.2.2 Control Module for Adaptive Cruise Control, Removing and Installing, from the Retaining Plate, Version 1...................................................................................5025 6.2.3 Control Module for Adaptive Cruise Control, Removing and Installing, with Retaining Plate, Version 2.......................................................................................5027 6.2.4 Control Module for Adaptive Cruise Control, Removing and Installing, from the Retaining Plate, Version 2...................................................................................5027 6.2.5 Control Module for Adaptive Cruise Control, Removing and Installing, From the Adapter Frame, Version 2.....................................................................................5029 6.3 Adaptive Cruise Control, Calibrating.............................................................................................................................................................5030 7 Special Tools..........................................................................................................................................................................................5031 90 – Instruments.............................................................................................................................................................................................5034 1 Instrument Cluster.....................................................................................................................................................................................5034 1.1 Overview - Instrument Cluster....................................................................................................................................................................5034 1.2 Instrument Cluster -KX2-, Removing and Installing................................................................................................................................................5034 2 Horn...................................................................................................................................................................................................5037 2.1 Overview - Horn..................................................................................................................................................................................5037 2.2 High Tone Horn -H2-/Low Tone Horn -H7-, Removing and Installing..................................................................................................................................5037 92 – Wiper/Washer Systems....................................................................................................................................................................................5039 1 Windshield Wiper System................................................................................................................................................................................5039 1.1 Overview - Windshield Wiper System...............................................................................................................................................................5039 1.1.1 Overview - Windshield Wiper System.........................................................................................................................................................5039 1.1.2 Overview - Windshield Wiper Motor and Windshield Wiper Frame...............................................................................................................................5041 1.2 Wiper, Moving Into Service Position..............................................................................................................................................................5042 1.3 Wiper Blade, Removing and Installing.............................................................................................................................................................5042 1.4 Windshield Wiper Arms, Removing and Installing...................................................................................................................................................5043 1.5 Windshield Wiper Arms, Adjusting.................................................................................................................................................................5044 1.6 Windshield Wiper Motor -V-, Removing and Installing..............................................................................................................................................5046 1.7 Windshield Wiper Motor, Replacing................................................................................................................................................................5047 1.8 Windshield Wiper Motor, Deactivating Alternating Park Position Function..........................................................................................................................5048 1.9 Rain/Light Recognition Sensor, Removing and Installing...........................................................................................................................................5049 1.9.1 Rain/Light Recognition Sensor, Removing and Installing, Vehicles with Front Camera for Assistance Systems..................................................................................5049 1.9.2 Rain/Light Recognition Sensor, Removing and Installing, Vehicles without Front Camera for Assistance Systems...............................................................................5052 1.10 Rain/Light Recognition Sensor, Servicing........................................................................................................................................................5055 1.10.1 Rain/Light Recognition Sensor, Servicing, TRW.............................................................................................................................................5055 1.10.2 Rain/Light Recognition Sensor, Servicing, Valeo...........................................................................................................................................5056 2 Windshield Washer System...............................................................................................................................................................................5059 2.1 Overview - Windshield Washer System..............................................................................................................................................................5059 2.1.1 Overview - Windshield Washer System, with Headlamp Washer System...........................................................................................................................5059 2.1.2 Overview - Windshield Washer System, with Headlamp Washer System...........................................................................................................................5061 2.1.3 Overview - Windshield Washer System, without Headlamp Washer System........................................................................................................................5063 2.2 Windshield Washer Fluid Reservoir, Removing and Installing.......................................................................................................................................5064 2.2.1 Windshield Washer Fluid Reservoir, Removing and Installing.................................................................................................................................5064 2.2.2 Windshield Washer Fluid Reservoir, Removing and Installing.................................................................................................................................5065 2.2.3 Auxiliary Component Bracket, Removing and Installing.......................................................................................................................................5067 2.3 Windshield Washer Fluid Level Sensor, Removing and Installing....................................................................................................................................5067 2.3.1 Windshield Washer Fluid Level Sensor, Removing and Installing..............................................................................................................................5067 2.3.2 Windshield Washer Fluid Level Sensor, Removing and Installing..............................................................................................................................5068 2.4 Windshield Washer Pump, Removing and Installing..................................................................................................................................................5069 2.4.1 Windshield Washer Pump, Removing and Installing............................................................................................................................................5069 2.4.2 Windshield Washer Pump, Removing and Installing............................................................................................................................................5069 2.5 Spray Nozzles, Removing and Installing...........................................................................................................................................................5070 2.6 Spray Nozzles, Adjusting.........................................................................................................................................................................5071 3 Rear Window Wiper System...............................................................................................................................................................................5072 3.1 Overview - Rear Window Wiper System..............................................................................................................................................................5072 3.2 Wiper Blade, Removing and Installing.............................................................................................................................................................5073 3.3 Windshield Wiper Arm, Removing and Installing....................................................................................................................................................5073 3.4 Wiper Arm, Adjusting.............................................................................................................................................................................5074 3.5 Rear Window Wiper Motor -V12-, Removing and Installing...........................................................................................................................................5074 4 Rear Window Washer System..............................................................................................................................................................................5076 4.1 Overview - Rear Window Washer System.............................................................................................................................................................5076 4.1.1 Overview - Rear Window Washer System, Golf.................................................................................................................................................5076 4.1.2 Overview - Rear Window Washer System, GTI and GTD..........................................................................................................................................5077 4.1.3 Overview - Rear Window Washer System.......................................................................................................................................................5078 4.2 Windshield Washer Fluid Reservoir, Removing and Installing.......................................................................................................................................5079 4.2.1 Windshield Washer Fluid Reservoir, Removing and Installing.................................................................................................................................5079 4.2.2 Windshield Washer Fluid Reservoir, Removing and Installing.................................................................................................................................5079 4.3 Rear Window Washer Pump, Removing and Installing.................................................................................................................................................5079 4.3.1 Rear Window Washer Pump, Removing and Installing...........................................................................................................................................5079 4.3.2 Rear Window Washer Pump, Removing and Installing...........................................................................................................................................5079 4.4 Spray Nozzle, Removing and Installing............................................................................................................................................................5080 4.4.1 Spray Nozzle, Removing and Installing, Golf................................................................................................................................................5080 4.4.2 Spray Nozzle, Removing and Installing......................................................................................................................................................5080 4.5 Spray Nozzle, Adjusting..........................................................................................................................................................................5081 5 Headlamp Washer System.................................................................................................................................................................................5082 5.1 Overview - Headlamp Washer System................................................................................................................................................................5082 5.1.1 Overview - Headlamp Washer System..........................................................................................................................................................5082 5.1.2 Overview - Headlamp Washer System..........................................................................................................................................................5083 5.2 Windshield Washer Fluid Reservoir, Removing and Installing.......................................................................................................................................5084 5.2.1 Windshield Washer Fluid Reservoir, Removing and Installing.................................................................................................................................5084 5.2.2 Windshield Washer Fluid Reservoir, Removing and Installing.................................................................................................................................5084 5.3 Headlamp Washer Pump -V11-, Removing and Installing..............................................................................................................................................5084 5.3.1 Headlamp Washer Pump -V11-, Removing and Installing........................................................................................................................................5084 5.3.2 Headlamp Washer Pump -V11-, Removing and Installing........................................................................................................................................5085 5.4 Lift Cylinder, Removing and Installing...........................................................................................................................................................5086 5.4.1 Lift Cylinder, Removing and Installing.....................................................................................................................................................5086 5.4.2 Lift Cylinder, Removing and Installing.....................................................................................................................................................5087 5.5 Spray Nozzles, Removing and Installing...........................................................................................................................................................5089 5.6 Spray Nozzles, Adjusting.........................................................................................................................................................................5089 6 Washer Fluid Hoses.....................................................................................................................................................................................5090 6.1 Washer Fluid Hoses, Servicing....................................................................................................................................................................5090 7 Special Tools..........................................................................................................................................................................................5091 94 – Exterior Lights, Switches...............................................................................................................................................................................5092 1 Headlamp...............................................................................................................................................................................................5093 1.1 Overview - Headlamp..............................................................................................................................................................................5093 1.1.1 Overview - Halogen Twin Headlamp...........................................................................................................................................................5094 1.1.2 Overview - HID Headlamp....................................................................................................................................................................5096 1.1.3 Overview - HID Headlamp for Cornering Lamp and LED Daytime Running Lamp....................................................................................................................5098 1.1.4 Overview - HID Headlamp with Dynamic High Beam Control and LED-Daytime Running Lamps.......................................................................................................5100 1.1.5 Overview - HID Headlamp with Dynamic High Beam Control and LED-Daytime Running Lamps.......................................................................................................5102 1.1.6 Overview - LED Headlamp....................................................................................................................................................................5104 1.1.7 Overview - Headlamp Housing Repair Kit, Excluding LED Headlamps............................................................................................................................5106 1.1.8 Overview - Headlamp Housing Repair Kit, LED Headlamps Only.................................................................................................................................5107 1.1.9 Overview - Daytime Running Lamps...........................................................................................................................................................5108 1.2 Headlamp, Removing and Installing................................................................................................................................................................5108 1.3 Headlamp, Adjusting..............................................................................................................................................................................5111 1.3.1 Halogen Twin Headlamp, Adjusting...........................................................................................................................................................5111 1.3.2 HID Headlamp, Adjusting....................................................................................................................................................................5111 1.3.3 LED Headlamp, Adjusting....................................................................................................................................................................5111 1.3.4 Fog Lamp, Adjusting........................................................................................................................................................................5111 1.3.5 Auxiliary Headlamps, Adjusting.............................................................................................................................................................5111 1.4 Headlamp Installed Position, Correcting..........................................................................................................................................................5111 1.5 Left/Right Front Turn Signal Bulb -M5-/-M7-, Removing and Installing.............................................................................................................................5113 1.5.1 Left/Right Front Turn Signal Bulb -M5-/-M7-, Removing and Installing, Halogen Twin Headlamp................................................................................................5113 1.5.2 Left/Right Front Turn Signal Bulb -M5-/-M7-, Removing and Installing, HID Headlamps........................................................................................................5114 1.6 Headlamp Housing Repair Kit, Installing..........................................................................................................................................................5115 1.6.1 Headlamp Housing Repair Kit, Installing, Excluding LED Headlamp............................................................................................................................5115 1.6.2 Headlamp Housing Repair Kit, Installing, LED Headlamp Only.................................................................................................................................5117 1.7 Headlamp, Changing from RHD to LHD...............................................................................................................................................................5118 1.7.1 Headlamp, Changing from RHD to LHD, Halogen Twin Headlamp..................................................................................................................................5118 1.7.2 Headlamp, Changing from RHD to LHD, HID Headlamps..........................................................................................................................................5119 1.7.3 Front Right Headlamp Adjusting to LHD Traffic, HID Headlamp for Cornering light and LED-Daytime Running Lamps..............................................................................5119 1.7.4 Front Right Headlamp Adjusting to LHD Traffic, HID Headlamp with Dynamic High Beam Control and LED-Daytime Running Lamps...................................................................5119 1.7.5 Headlamp, Changing from RHD to LHD, LED Headlamps..........................................................................................................................................5120 1.8 Headlamp, Changing from LHD to RHD...............................................................................................................................................................5120 1.8.1 Headlamp, Changing from LHD to RHD, Halogen Twin Headlamp..................................................................................................................................5120 1.8.2 Headlamp, Changing from LHD to RHD, HID Headlamps..........................................................................................................................................5120 1.8.3 Front Left Headlamp Adjusting to RHD Traffic, HID Headlamp for Cornering light and LED-Daytime Running Lamps...............................................................................5121 1.8.4 Front Left Headlamp Adjusting to RHD Traffic, HID Headlamp with Dynamic High Beam Control and LED-Daytime Running Lamps....................................................................5121 1.8.5 Headlamp, Changing from LHD to RHD, LED Headlamps..........................................................................................................................................5122 1.9 Left/Right Headlamp Beam Adjustment Motor -V48-/-V49-, Removing and Installing...................................................................................................................5122 1.9.1 Left/Right Headlamp Beam Adjustment Motor -V48-/-V49-, Removing and Installing, Halogen Twin Headlamps.....................................................................................5122 1.9.2 Left/Right Headlamp Beam Adjustment Motor -V48-/-V49-, Removing and Installing, HID Headlamps..............................................................................................5124 1.9.3 Left/Right Headlamp Beam Adjustment Motor -V48-/-V49-, Removing and Installing, LED Headlamps..............................................................................................5125 1.10 Low Beam Headlamp Bulb, Removing and Installing.................................................................................................................................................5127 1.10.1 Low Beam Headlamp Bulb, Removing and Installing, Halogen Twin Headlamp....................................................................................................................5127 1.10.2 Low Beam Headlamp Bulb, Removing and Installing, LED Headlamp.............................................................................................................................5128 1.11 Left/Right High Beam Headlamp Bulb -M30-/-M32-, Removing and Installing.........................................................................................................................5132 1.11.1 High Beam Headlamp Bulb -M30-/-M32-, Removing and Installing, Halogen Twin Headlamp.......................................................................................................5132 1.11.2 Left/Right High Beam Headlamp Bulb -M30-/-M32-, Removing and Installing, LED Headlamp.....................................................................................................5133 1.12 Left/Right HID Headlamp Bulb -L13-/-L14-, Removing and Installing...............................................................................................................................5135 1.13 Left/Right Position Lamp Bulb -M1-/-M3-, Removing and Installing................................................................................................................................5137 1.13.1 Left/Right Position Lamp Bulb -M1-/-M3-, Removing and Installing, Halogen Twin Headlamp...................................................................................................5137 1.13.2 Left/Right Position Lamp Bulb -M1-/-M3-, Removing and Installing, HID Headlamp............................................................................................................5137 1.14 Left/Right Daytime Running Lamp Bulb -L174-/-L175-, Removing and Installing.....................................................................................................................5137 1.14.1 Left/Right Daytime Running Lamp Bulb -L174-/-L175-, Removing and Installing, Halogen Twin Headlamp........................................................................................5137 1.14.2 Left/Right Daytime Running Lamp Bulb -L174-/-L175-, Removing and Installing, HID Headlamp.................................................................................................5138 1.15 Left/Right Daytime Running Lamp and Position Lamp LED Module -L176-/-L177-, Removing and Installing.............................................................................................5139 1.15.1 Left/Right Daytime Running Lamp and Position Lamp LED Module -L176-/-L177-, Removing and Installing.......................................................................................5139 1.15.2 Left/Right Daytime Running Lamp and Position Lamp LED Module -L176-/-L177-, Removing and Installing, “GTE” Only...........................................................................5139 1.16 Left/Right Low Beam Headlamp Reflector Motor -V294-/-V295-, Removing and Installing.............................................................................................................5140 1.17 Left/Right Cornering Lamp Bulb -L148-/-L149-, Removing and Installing...........................................................................................................................5140 1.18 Left/Right HID Headlamp Control Module -J343-/-J344-, Removing and Installing...................................................................................................................5141 1.19 Left/Right Headlamp Power Output Stage -J667-/-J668-, Removing and Installing...................................................................................................................5142 1.20 Left/Right Daytime Running Lamp and Position Lamp Control Module -J860-/-J861-, Removing and Installing.........................................................................................5143 1.21 Headlamp Power Output Stage 2, Removing and Installing..........................................................................................................................................5144 1.22 Left/Right LED Headlamp Power Output Module 1 -A31-/-A32-, Removing and Installing..............................................................................................................5145 1.23 Sensor for Left/Right Variable Headlamp Positioning Motor -G695-/-G696-, Removing and Installing................................................................................................5146 1.24 Left/Right Variable Headlamp Positioning Motor -V446-/-V447-, Removing and Installing...........................................................................................................5146 1.25 Left/Right Swivel Module Position Sensor -G474-/-G475-, Removing and Installing.................................................................................................................5147 1.26 Left/Right Adaptive Cornering Lamp Motor -V318-/-V319-, Removing and Installing.................................................................................................................5147 2 Fog Lamp...............................................................................................................................................................................................5148 2.1 Overview - Fog Lamps.............................................................................................................................................................................5148 2.1.1 Overview - Fog Lamps, Golf.................................................................................................................................................................5148 2.1.2 Overview - Fog Lamp, GTI and GTD...........................................................................................................................................................5149 2.2 Fog Lamp, Removing and Installing................................................................................................................................................................5149 2.2.1 Fog Lamp, Removing and Installing, Golf....................................................................................................................................................5149 2.2.2 Fog Lamp, Removing and Installing, GTI and GTD.............................................................................................................................................5150 2.3 Left/Right Front Fog Lamp Bulb -L22-/-L23-, Removing and Installing..............................................................................................................................5151 3 Exterior Rearview Mirror Lamps.........................................................................................................................................................................5152 3.1 Overview - Exterior Rearview Mirror Lamps........................................................................................................................................................5152 3.2 Turn Signal, Removing and Installing.............................................................................................................................................................5153 3.3 Entry Lamp in Exterior Rearview Mirror, Removing and Installing..................................................................................................................................5154 4 Tail Lamps.............................................................................................................................................................................................5156 4.1 Overview - Body Tail Lamps.......................................................................................................................................................................5156 4.1.1 Overview - Body Tail Lamps, with Bulbs.....................................................................................................................................................5156 4.1.2 Overview - Body Tail Lamps, with LED.......................................................................................................................................................5158 4.2 Overview - Rear Lid Tail Lamps...................................................................................................................................................................5159 4.2.1 Overview - Rear Lid Tail Lamps, with Bulbs.................................................................................................................................................5159 4.2.2 Overview - Rear Lid Tail Lamps, with LED...................................................................................................................................................5160 4.3 Rear Lid Tail Lamp, Removing and Installing......................................................................................................................................................5160 4.4 Tail Lamp, Correcting Installed Position.........................................................................................................................................................5161 4.5 Tail Lamp, Removing and Installing...............................................................................................................................................................5162 4.6 Right/Left Tail Lamp Bulb -M2-/-M4-, Removing and Installing.....................................................................................................................................5163 4.7 Left/Right Rear Fog Lamp Bulb -L46-/-L47-, Removing and Installing...............................................................................................................................5164 4.8 Left/Right Brake/Tail Lamp Bulb -M21-/-M22-, Removing and Installing.............................................................................................................................5165 4.9 Back-Up Lamp, Removing and Installing............................................................................................................................................................5166 4.10 Turn Signal Bulb, Removing and Installing.......................................................................................................................................................5167 5 High-Mounted Brake Lamp................................................................................................................................................................................5169 5.1 Overview - High-Mounted Brake Lamp...............................................................................................................................................................5169 5.1.1 Overview - High-Mounted Brake Lamp, Golf...................................................................................................................................................5169 5.1.2 Overview - High-Mounted Brake Lamp.........................................................................................................................................................5170 5.2 High-Mounted Brake Lamp, Removing and Installing.................................................................................................................................................5170 5.2.1 High-Mounted Brake Lamp, Removing and Installing, Golf.....................................................................................................................................5170 5.2.2 High-Mounted Brake Lamp, Removing and Installing...........................................................................................................................................5172 6 License Plate Lamp.....................................................................................................................................................................................5173 6.1 Left/Right License Plate Lamp -X4-/-X5-, Removing and Installing.................................................................................................................................5173 6.2 Left/Right License Plate Lamp Bulb -X4-/-X5-, Removing and Installing............................................................................................................................5173 7 Access/Start Authorization.............................................................................................................................................................................5175 7.1 Overview - Access/Start Authorization System.....................................................................................................................................................5175 7.1.1 Overview - Access/Start Authorization System...............................................................................................................................................5175 7.1.2 Component Location Overview - Access/Start Authorization System, RHD.......................................................................................................................5177 7.2 Overview - Keyless Access Authorization System...................................................................................................................................................5178 7.2.1 Overview - Front Keyless Access Authorization System.......................................................................................................................................5178 7.2.2 Overview - Rear Keyless Access Authorization System........................................................................................................................................5179 7.2.3 Component Location Overview - Front Keyless Access Authorization System, RHD...............................................................................................................5180 7.2.4 Component Location Overview - Rear Keyless Access Authorization System, RHD................................................................................................................5181 7.3 Access/Start System Interface -J965-, Removing and Installing....................................................................................................................................5181 7.4 Driver Exterior/Front Passenger Exterior Door Handle Touch Sensor -G415-/-G416-, Removing and Installing.........................................................................................5182 7.5 Access/Start System Antenna 1 in Vehicle Interior -R138-, Removing and Installing................................................................................................................5183 7.6 Driver Access/Start System Antenna -R134-, Removing and Installing...............................................................................................................................5183 7.7 Front Passenger Access/Start System Antenna -R135-, Removing and Installing......................................................................................................................5183 7.8 Access/Start System Antenna in Luggage Compartment -R137-, Removing and Installing...............................................................................................................5183 7.9 Access/Start System Antenna in Rear Bumper -R136-, Removing and Installing.......................................................................................................................5184 8 Steering Column Switch Module..........................................................................................................................................................................5185 8.1 Overview - Steering Column Switch Module.........................................................................................................................................................5185 8.1.1 Overview - Steering Column Switch Module, with Mechanical Ignition Switch..................................................................................................................5185 8.1.2 Overview - Steering Column Switch Module, with Electronic Ignition Switch..................................................................................................................5187 8.2 Lock Cylinder, Removing and Installing...........................................................................................................................................................5188 8.3 Ignition Switch Key Lock Solenoid -N376-, Removing and Installing................................................................................................................................5189 8.4 Ignition/Starter Switch, Removing and Installing.................................................................................................................................................5190 8.5 Steering Column Switch Module, Removing and Installing...........................................................................................................................................5191 8.5.1 Steering Column Switch Module, Removing and Installing, Kostal.............................................................................................................................5191 8.5.2 Steering Column Switch Module, Removing and Installing, Valeo..............................................................................................................................5193 8.6 Steering Column Electronics Control Module -J527-, Removing and Installing.......................................................................................................................5196 8.6.1 Steering Column Electronics Control Module -J527-, Removing and Installing, Kostal.........................................................................................................5196 8.6.2 Steering Column Electronics Control Module -J527-, Removing and Installing, Valeo..........................................................................................................5198 8.7 Turn Signal Switch -E2-, Removing and Installing.................................................................................................................................................5201 8.7.1 Turn Signal Switch -E2-, Removing and Installing, Kostal...................................................................................................................................5201 8.7.2 Turn Signal Switch -E2-, Removing and Installing, Valeo....................................................................................................................................5202 8.8 Cruise Control Switch -E45-, Removing and Installing.............................................................................................................................................5203 8.9 Windshield Wiper Intermittent Mode Switch -E22-, Removing and Installing.........................................................................................................................5203 8.10 Anti-Theft Immobilizer Reader Coil -D2-, Removing and Installing................................................................................................................................5204 8.10.1 Anti-Theft Immobilizer Reader Coil -D2-, Removing and Installing, Vehicle with Ignition Key...............................................................................................5204 8.10.2 Anti-Theft Immobilizer Reader Coil -D2-, Removing and Installing, Vehicle with Keyless Access.............................................................................................5204 8.11 Steering Lock Housing, Removing and Installing..................................................................................................................................................5204 9 Parking Aid............................................................................................................................................................................................5206 9.1 Overview - Parking Aid...........................................................................................................................................................................5206 9.1.1 Overview - Front Parking Aid...............................................................................................................................................................5206 9.1.2 Overview - Rear Parking Aid................................................................................................................................................................5207 9.1.3 Overview - Front Parking Aid, RHD..........................................................................................................................................................5208 9.1.4 Overview - Rear Parking Aid, RHD...........................................................................................................................................................5209 9.2 Parking Aid Control Module -J446-, Removing and Installing.......................................................................................................................................5210 9.2.1 Parking Aid Control Module -J446- Removing and Installing..................................................................................................................................5210 9.2.2 Parking Aid Control Module -J446- Removing and Installing, RHD.............................................................................................................................5210 9.3 Front Parking Aid Warning Buzzer -H22-, Removing and Installing..................................................................................................................................5211 9.3.1 Front Parking Aid Warning Buzzer -H22-, Removing and Installing............................................................................................................................5211 9.3.2 Front Parking Aid Warning Buzzer -H22-, Removing and Installing, RHD.......................................................................................................................5212 9.4 Rear Parking Aid Warning Buzzer -H15-, Removing and Installing...................................................................................................................................5212 9.5 Front Parking Aid Sensor, Removing and Installing................................................................................................................................................5213 9.6 Rear Parking Aid Sensor, Removing and Installing.................................................................................................................................................5214 10 Parallel Parking Assist...............................................................................................................................................................................5215 10.1 Overview - Parallel Parking Assist..............................................................................................................................................................5215 10.1.1 Overview - Parallel Parking Assist........................................................................................................................................................5215 10.1.2 Overview - Parallel Parking Assist, RHD...................................................................................................................................................5216 10.2 Control Module, Removing and Installing.........................................................................................................................................................5216 10.3 Front Sensor, Removing and Installing...........................................................................................................................................................5216 10.4 Rear Sensor, Removing and Installing............................................................................................................................................................5217 11 Automatic Headlamp Range Control......................................................................................................................................................................5218 11.1 Overview - Automatic Head Lamp Range Control....................................................................................................................................................5218 11.1.1 Overview - Automatic Head Lamp Range Control..............................................................................................................................................5218 11.1.2 Overview - Automatic Head Lamp Range Control, RHD.........................................................................................................................................5219 11.2 Headlamp Range Control Module -J431-/Cornering Lamp and Headlamp Range Control Module -J745-, Removing and Installing...........................................................................5220 11.2.1 Headlamp Range Control Module -J431-/Cornering Lamp and Headlamp Range Control Module -J745-, Removing and Installing.....................................................................5220 11.2.2 Headlamp Range Control Module -J431-/Cornering Lamp and Headlamp Range Control Module -J745-, Removing and Installing, RHD................................................................5221 12 Trailer Hitch.........................................................................................................................................................................................5223 12.1 Overview - Trailer Hitch Socket.................................................................................................................................................................5223 12.2 Trailer Socket -U10-............................................................................................................................................................................5223 12.3 Towing Recognition Control Module -J345-, Removing and Installing...............................................................................................................................5224 13 Blind Spot Detection..................................................................................................................................................................................5225 13.1 Overview - Blind Spot Detection.................................................................................................................................................................5225 13.2 Blind Spot Detection Warning Lamp in Left/Right Exterior Mirror -K303-/-K304-, Removing and Installing..........................................................................................5226 13.3 Blind Spot Detection Control Module -J1086-/Blind Spot Detection Control Module 2 -J1087-, Removing and Installing..............................................................................5226 13.4 Blind Spot Detection, Calibrating...............................................................................................................................................................5227 13.4.1 Preparing for Calibration.................................................................................................................................................................5227 13.4.2 Preparing for Calibration.................................................................................................................................................................5228 13.4.3 Blind Spot Detection Control Module -J1086-/Blind Spot Detection Control Module 2 -J1087-, Calibrating....................................................................................5232 14 Special Tools.........................................................................................................................................................................................5234 96 – Interior Lights, Switches...............................................................................................................................................................................5236 1 Lamps..................................................................................................................................................................................................5236 1.1 Overview - Instrument Panel Lamps................................................................................................................................................................5236 1.2 Overview - Front Door Lamps......................................................................................................................................................................5238 1.3 Overview - Rear Door Lamps.......................................................................................................................................................................5239 1.4 Overview - Center Console Lamps..................................................................................................................................................................5240 1.5 Overview - Luggage Compartment Lamps.............................................................................................................................................................5241 1.6 Overview - Roof Trim Panel Lamps.................................................................................................................................................................5242 1.7 Glove Compartment Lamp -W6-, Removing and Installing.............................................................................................................................................5243 1.8 Glove Compartment Lamp -W6- Bulb, Replacing......................................................................................................................................................5243 1.9 Left/Right Front Footwell Lamp -K268-/-K269-, Removing and Installing............................................................................................................................5244 1.9.1 Left Front Footwell Lamp -K268-, Removing and Installing, Driver Side......................................................................................................................5244 1.9.2 Right Front Footwell Lamp -K269-, Removing and Installing, Front Passenger Side............................................................................................................5245 1.10 Left/Right Front Footwell Illumination Bulb -L151-/-L152-, Removing and Installing..............................................................................................................5245 1.11 Central Locking -SAFE- Indicator Lamp -K133-, Removing and Installing...........................................................................................................................5246 1.12 Left/Right Front Entry Lamp -W31-/-W32-, Removing and Installing................................................................................................................................5246 1.13 Driver/Front Passenger Door Warning Lamp -W30-/-W36-, Removing and Installing...................................................................................................................5248 1.14 Driver/Front Passenger Door Opener Illumination Bulb -L108-/-L109-, Removing and Installing.....................................................................................................5248 1.15 Left/Right Front Door Ambient Lighting Bulb 2 -L203-/-L204-, Removing and Installing............................................................................................................5249 1.16 Left/Right Rear Entry Lamp -W33-/-W34-, Removing and Installing.................................................................................................................................5249 1.17 Left/Right Rear Door Warning Lamp -W37-/-W38-, Removing and Installing..........................................................................................................................5250 1.18 Selector Lever Transmission Range Position Display Unit -Y26-, Removing and Installing..........................................................................................................5250 1.19 Luggage Compartment Lamp -W3-, Removing and Installing..........................................................................................................................................5250 1.20 Driver/Front Passenger Vanity Mirror Lamp -W20-/-W14-, Removing and Installing..................................................................................................................5251 1.21 Front Interior Lamp -W1- Bulb, Removing and Installing..........................................................................................................................................5252 1.21.1 Front Interior Lamp -W1- Bulb, Removing and Installing, with LED-Technology...............................................................................................................5252 1.21.2 Front Interior Lamp -W1- Bulb, Removing and Installing, with Bulbs........................................................................................................................5253 1.22 Rear Interior Lamp -W43- Bulb Removing and Installing...........................................................................................................................................5254 1.22.1 Rear Interior Lamp -W43- Bulb Removing and Installing, with Bulbs.........................................................................................................................5254 1.22.2 Rear Interior Lamp -W43- Bulb Removing and Installing, with LED-Technology................................................................................................................5255 1.23 Left/Right Rear Reading Lamp -W11-/-W12- Removing and Installing................................................................................................................................5255 1.24 Ambient Lighting LED, Removing and Installing...................................................................................................................................................5255 1.24.1 Fiber Optic Cable for Left Front Sill Panel Ambient Lighting -W67-/Fiber Optic Cable for Right Front Sill Panel Ambient Lighting -W68-, Removing and Installing...........................5255 2 Controls...............................................................................................................................................................................................5258 2.1 Overview - Instrument Panel Controls.............................................................................................................................................................5259 2.2 Overview - Front Door Controls...................................................................................................................................................................5260 2.3 Overview - Rear Door Controls....................................................................................................................................................................5261 2.4 Overview - Center Console Controls...............................................................................................................................................................5262 2.5 Overview - Luggage Compartment Controls..........................................................................................................................................................5263 2.6 Overview - Roof Trim Panel Controls..............................................................................................................................................................5264 2.7 Rotary Light Switch -EX1-, Removing and Installing...............................................................................................................................................5265 2.8 Headlamp Range Control Adjuster -E102-, Removing and Installing..................................................................................................................................5265 2.9 Driving Profile Selection Button -E735-, Removing and Installing.................................................................................................................................5266 2.10 Start/Stop Mode Button -E693-, Removing and Installing..........................................................................................................................................5266 2.11 ASR/ESP Button -E256-, Removing and Installing..................................................................................................................................................5266 2.12 Parking Aid Button -E266-, Removing and Installing..............................................................................................................................................5266 2.13 Parallel Parking Assistance Button -E581-, Removing and Installing..............................................................................................................................5266 2.14 Driving Profile Selection Button -E735-, Removing and Installing................................................................................................................................5267 2.15 Center Console Switch Module 1 -EX23-/Center Console Switch Module 2 -EX30-, Removing and Installing............................................................................................5267 2.16 Emergency Flasher Switch -EX3-, Removing and Installing.........................................................................................................................................5268 2.17 Left/Right Seat Heating Button -E653-/-E654-, Removing and Installing...........................................................................................................................5269 2.18 Glove Compartment Lamp Switch -E26-, Removing and Installing....................................................................................................................................5269 2.19 Exterior Rearview Mirror Adjuster -EX11-, Removing and Installing...............................................................................................................................5270 2.20 Power Window Control Head In Driver Door -E512-, Removing and Installing........................................................................................................................5270 2.21 Front Passenger Power Window Button -E716-, Removing and Installing.............................................................................................................................5271 2.22 Driver Interior Locking Button -E308-, Removing and Installing..................................................................................................................................5271 2.23 Fuel Filler Door Release Button -E319-, Removing and Installing.................................................................................................................................5272 2.24 Interior Monitoring And Vehicle Inclination Deactivation Button -E616-, Removing and Installing.................................................................................................5272 2.25 Driver/Front Passenger Door Contact Switch -F2-/-F3-, Removing and Installing...................................................................................................................5273 2.26 Left/Right Rear Power Window Switch in Left Rear Door -E52-/-E54-, Removing and Installing......................................................................................................5273 2.27 Left/Right Rear Door Contact Switch -F10-/-F11-, Removing and Installing........................................................................................................................5274 2.28 Electromechanical Parking Brake Button -E538-/ -AUTO HOLD- Button -E540-, Removing and Installing...............................................................................................5274 2.29 Start System Button -E378-, Removing and Installing.............................................................................................................................................5275 2.30 Rear Lid Alarm Switch -F123-, Removing and Installing...........................................................................................................................................5275 2.31 Driver/Front Passenger Vanity Mirror Lamp Contact Switch -F147-/-F148-, Removing and Installing.................................................................................................5275 2.32 Sunroof Button -E325-, Removing and Installing..................................................................................................................................................5276 2.33 Front Interior Lamp/Reading Lamp, Removing and Installing.......................................................................................................................................5276 2.34 Rear Interior/Reading Lamp, Removing and Installing.............................................................................................................................................5277 2.35 Right Front Reading Lamp Button -E634-, Removing and Installing.................................................................................................................................5278 3 Anti-Theft Alarm System................................................................................................................................................................................5279 3.1 Overview - Interior Monitoring...................................................................................................................................................................5279 3.1.1 Overview - Interior Monitoring.............................................................................................................................................................5279 3.1.2 Overview - Interior Monitoring, RHD........................................................................................................................................................5280 3.2 Alarm Horn -H12-, Removing and Installing........................................................................................................................................................5281 3.3 Anti-Theft Alarm System Sensor -G578-, Removing and Installing...................................................................................................................................5282 3.3.1 Anti-Theft Alarm System Sensor -G578-, Removing and Installing Versions with Two Bolts.....................................................................................................5282 3.3.2 Anti-Theft Alarm System Sensor -G578-, Removing and Installing Versions with Four Bolts....................................................................................................5283 4 Driver Assistance Systems Front Camera.................................................................................................................................................................5285 4.1 Driver Assistance Systems Front Camera, Removing and Installing..................................................................................................................................5285 5 Cigarette Lighter and Socket...........................................................................................................................................................................5286 5.1 Cigarette Lighter -U1-, Removing and Installing..................................................................................................................................................5286 5.2 Socket Illumination Bulb -L42-, Removing and Installing..........................................................................................................................................5286 5.3 Rear Cigarette Lighter Illumination Bulb -L32-, Removing and Installing..........................................................................................................................5286 5.4 Socket -U-, Removing and Installing..............................................................................................................................................................5286 6 Special Tools..........................................................................................................................................................................................5287 97 – Wiring..................................................................................................................................................................................................5288 1 Relay Carriers, Fuse Panels and E-Boxes................................................................................................................................................................5288 1.1 Overview - Relay Carriers, Fuse Panels and E-Boxes...............................................................................................................................................5288 1.1.1 Relay Panels, Fuse Panels and E-Boxes......................................................................................................................................................5288 1.1.2 Relay Carrier, Fuse Panel Instrument Panel/A-Pillar........................................................................................................................................5290 1.1.3 Relay Carrier, Fuse Panel Instrument Panel/A-Pillar, RHD...................................................................................................................................5291 1.1.4 Component Location Overview - Battery Fuse Panel, Vehicles with High Voltage System........................................................................................................5292 1.2 E-Box, Removing and Installing...................................................................................................................................................................5292 1.3 E-Box Relay and Fuse Panels, Removing and Installing.............................................................................................................................................5294 1.3.1 Fuse Panel B -SB-, Removing and Installing.................................................................................................................................................5294 1.3.2 Fuse Panel A -SA-, Removing and Installing.................................................................................................................................................5296 1.4 Relay and Fuse Panels Behind Instrument Panel, Removing and Installing...........................................................................................................................5296 1.4.1 Relay and Fuse Panels Behind Instrument Panel, Removing and Installing.....................................................................................................................5296 1.4.2 Relay and Fuse Panels Behind Instrument Panel, Removing and Installing, RHD................................................................................................................5297 1.5 Battery Fuse Panel, Removing and Installing......................................................................................................................................................5298 2 Control Modules........................................................................................................................................................................................5299 2.1 Component Location Overview - Control Modules....................................................................................................................................................5299 2.1.1 Component Location Overview - Front Control Module.........................................................................................................................................5299 2.1.2 Component Location Overview - Front Control Module, RHD....................................................................................................................................5301 2.1.3 Component Location Overview - Rear Control Module..........................................................................................................................................5302 2.2 Overview - Control Modules.......................................................................................................................................................................5303 2.2.1 Overview - Control Modules.................................................................................................................................................................5303 2.2.2 Overview - Control Modules, RHD............................................................................................................................................................5304 2.3 Overview - Data Bus On Board Diagnostic Interface................................................................................................................................................5305 2.4 Vehicle Electrical System Control Module -J519-, Removing and Installing.........................................................................................................................5305 2.4.1 Vehicle Electrical System Control Module -J519-, Removing and Installing...................................................................................................................5305 2.4.2 Vehicle Electrical System Control Module -J519-, Removing and Installing, RHD..............................................................................................................5307 2.5 Data Bus On Board Diagnostic Interface -J533-, Removing and Installing...........................................................................................................................5308 2.6 Vehicle Electrical System Control Module -J519- Bracket, Removing and Installing.................................................................................................................5309 2.6.1 Vehicle Electrical System Control Module -J519- Bracket, Removing and Installing...........................................................................................................5309 2.6.2 Vehicle Electrical System Control Module -J519- Bracket, Removing and Installing, RHD......................................................................................................5310 2.7 Vehicle Electrical System Control Module -J519- Bracket, Replacing...............................................................................................................................5311 2.7.1 Vehicle Electrical System Control Module -J519- Bracket, Replacing.........................................................................................................................5311 2.7.2 Vehicle Electrical System Control Module -J519- Bracket, Replacing, RHD....................................................................................................................5311 2.8 Parking Aid Control Module -J446-/Parallel Parking Assistance Control Module -J791- Bracket, Removing and Installing.............................................................................5312 2.9 Engine Sound Generator Control Module -J943- Removing and Installing, Vehicles with Active Sound, Golf GTD.......................................................................................5312 3 Connectors.............................................................................................................................................................................................5313 3.1 Wiring Harnesses and Connectors, Repairing.......................................................................................................................................................5313 3.1.1 Electric Wiring Harnesses and Connectors, Repairing........................................................................................................................................5313 3.1.2 Connector Housings and Connectors, Repairing...............................................................................................................................................5313 4 Connector Housings, Releasing and Disassembling........................................................................................................................................................5314 5 Antenna Wires, Repairing...............................................................................................................................................................................5315 6 Fiber-Optic Cable......................................................................................................................................................................................5316 7 Vehicle Diagnostic Tester..............................................................................................................................................................................5317 8 Revision History.......................................................................................................................................................................................5318 09-03 Communication..............................................................................................................................................................................................5322 00 – General, Technical Data.................................................................................................................................................................................5326 1 Repair Information.....................................................................................................................................................................................5326 1.1 General Repair Information.......................................................................................................................................................................5326 1.2 CAN Bus Wires Repair Information.................................................................................................................................................................5326 1.3 Transmitted Output, Antenna Installation Locations...............................................................................................................................................5326 91 – Communication...........................................................................................................................................................................................5328 1 Infotainment System....................................................................................................................................................................................5328 1.1 Overview - Infotainment System...................................................................................................................................................................5328 1.2 Component Location Overview - Infotainment System................................................................................................................................................5336 1.3 Infotainment System Display, Removing and Installing.............................................................................................................................................5337 1.4 Information Electronics Control Module 1 -J794-, Removing and Installing.........................................................................................................................5338 2 Sound System...........................................................................................................................................................................................5340 2.1 Component Location Overview - Sound Systems......................................................................................................................................................5340 2.1.1 Component Location Overview - Sound System, Vehicles with Volkswagen Sound System..........................................................................................................5340 2.1.2 Component Location Overview - Sound System, Vehicles with Dynaudio Sound System............................................................................................................5342 2.2 Digital Sound System Control Module -J525-.......................................................................................................................................................5343 2.2.1 Digital Sound System Control Module -J525-, Vehicles with Volkswagen Sound System..........................................................................................................5343 2.2.2 Digital Sound System Control Module -J525-, Vehicles with Dynaudio Sound System............................................................................................................5345 2.2.3 Digital Sound System Control Module -J525-, Removing and Installing, eGolf.................................................................................................................5346 2.3 Digital Sound System Control Module -J525- Bracket, Removing and Installing......................................................................................................................5347 2.4 Left/Right Front Treble Speaker - R20 -/- R22 -, Removing and Installing.........................................................................................................................5348 2.5 Left/Right Rear Treble Speaker - R14 -/- R16 -, Removing and Installing..........................................................................................................................5348 2.5.1 Left/Right Rear Treble Speaker - R14 -/- R16 -, Removing and Installing, 2-Door Vehicles...................................................................................................5348 2.5.2 Left/Right Rear Treble Speaker - R14 -/- R16 -, Removing and Installing, 4-Door Vehicles...................................................................................................5349 2.6 Left/Right Front Bass Speaker - R21 -/- R23 -, Removing and Installing...........................................................................................................................5350 2.7 Left/Right Rear Bass Speaker - R15 -/- R17 -, Removing and Installing............................................................................................................................5351 2.7.1 Left/Right Rear Bass Speaker - R15 -/- R17 -, Removing and Installing, 2-Door Vehicles.....................................................................................................5351 2.7.2 Left/Right Rear Bass Speaker - R15-/- R17-, Removing and Installing, 4-Door Vehicles.......................................................................................................5352 2.8 Subwoofer - R211-, Removing and Installing.......................................................................................................................................................5353 3 Antenna Systems........................................................................................................................................................................................5354 3.1 Component Location Overview - Antenna Systems....................................................................................................................................................5354 3.2 Antenna Amplifier -R24- / Radio Antenna 2 -R93- / TV Antenna Amplifier 3 -R84-, Removing and Installing..........................................................................................5355 3.3 AM Frequency Filter -R177-, Removing and Installing..............................................................................................................................................5356 3.4 FM Frequency Filter In Negative Wire -R178- / FM Frequency Filter In Positive Wire -R179-, Removing and Installing...............................................................................5357 3.5 Roof Antenna -RX5-, Removing and Installing......................................................................................................................................................5358 4 Radio..................................................................................................................................................................................................5360 4.1 Overview - Radio.................................................................................................................................................................................5360 4.1.1 Overview - Radio, Composition Touch and Composition Color Radio Equipment Levels...........................................................................................................5360 4.1.2 Overview - Radio, Composition Media Radio Equipment Level..................................................................................................................................5360 4.1.3 Overview - Radio, Discover Pro Radio Equipment Level.......................................................................................................................................5360 4.2 Radio, Removing and Installing...................................................................................................................................................................5361 4.2.1 Radio -R-, Removing and Installing, Composition Touch and Composition Color Equipment Levels...............................................................................................5361 4.2.2 Radio -R -, Removing and Installing, Composition Media and Discover Media or Discover Pro Equipment Levels.................................................................................5362 5 Telephone System.......................................................................................................................................................................................5363 5.1 Cell Phone Preparation...........................................................................................................................................................................5363 5.1.1 Cell Phone Preparation, Bluetooth Hands-Free Calling.......................................................................................................................................5363 5.1.2 Cell Phone Preparation, Online Bluetooth Car Phone.........................................................................................................................................5363 5.2 Component Location Overview - Telephone System...................................................................................................................................................5364 5.3 Telephone Microphone -R38-, Removing and Installing..............................................................................................................................................5365 5.4 Cellular Telephone Amplifier -R86-, Removing and Installing......................................................................................................................................5366 5.5 Cellular Telephone Amplifier -R86- Bracket, Removing and Installing..............................................................................................................................5366 6 Navigation System......................................................................................................................................................................................5368 6.1 Overview - Navigation System.....................................................................................................................................................................5368 6.2 Component Location Overview - Navigation System..................................................................................................................................................5368 6.3 Navigation System Control Module, Removing and Installing........................................................................................................................................5369 7 TV System..............................................................................................................................................................................................5370 7.1 Component Location Overview - TV System..........................................................................................................................................................5370 7.2 TV Tuner, Removing and Installing................................................................................................................................................................5370 7.2.1 TV Tuner, Removing and Installing, Golf....................................................................................................................................................5370 7.2.2 TV Tuner, Removing and Installing, eGolf...................................................................................................................................................5372 8 Rearview Camera System.................................................................................................................................................................................5373 8.1 Overview - Rearview Camera System................................................................................................................................................................5373 8.2 Component Location Overview - Rearview Camera System.............................................................................................................................................5373 8.3 Overview - Rearview Camera System................................................................................................................................................................5375 8.4 Rearview Camera -R189-, Removing and Installing..................................................................................................................................................5375 9 Multifunction Steering Wheel...........................................................................................................................................................................5379 9.1 Overview - Multifunction Steering Wheel..........................................................................................................................................................5379 9.2 Overview - Multifunction Steering Wheel..........................................................................................................................................................5379 9.3 Right/Left Multifunction Buttons On Steering Wheel -E441 -/-E440 -, Removing and Installing......................................................................................................5380 9.4 Tiptronic Downshift Button on Steering Wheel - E439- / Tiptronic Upshift Button on Steering Wheel - E438-, Removing and Installing...............................................................5382 10 Connection for External Multimedia Devices............................................................................................................................................................5384 10.1 Connection for External Multimedia Devices, Removing and Installing.............................................................................................................................5384 10.1.1 Connection for External Multimedia Devices, Removing and Installing, in Front Center Console Storage Compartment..........................................................................5384 10.1.2 Connection for External Multimedia Devices, Removing and Installing, in Front Armrest Storage Compartment.................................................................................5385 10.2 USB Distributor -R293-, Removing and Installing.................................................................................................................................................5386 11 Mobile Online Services................................................................................................................................................................................5387 11.1 General Information.............................................................................................................................................................................5387 11.2 Component Location Overview - Mobile Online Services............................................................................................................................................5387 11.2.1 Component Location Overview - Mobile Online Services......................................................................................................................................5387 11.2.2 Component Location Overview - Mobile Online Services, eGolf and GTE.......................................................................................................................5389 11.3 Control Module for Emergency Call Module and Communication Unit -J949-, Removing and Installing.................................................................................................5389 11.3.1 Control Module for Emergency Call Module and Communication Unit -J949-, Removing and Installing, eGolf and GTE............................................................................5389 11.4 Control Module for Emergency Call Module and Communication Unit -J949-, Replacing...............................................................................................................5390 12 Special Tools.........................................................................................................................................................................................5393 13 Revision History......................................................................................................................................................................................5395 10-Electrical Wiring Diagrams & Locations.pdf (p.5399-7862)..........................................................................................................................................................5399 10-01 Electrical Wiring Diagrams.................................................................................................................................................................................5399 10-02 Electrical Wiring Diagrams 2...............................................................................................................................................................................7311 10-03 Electrical Fitting & Locations.............................................................................................................................................................................7556
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