Volkswagen Arteon 2021 Repair Manual – PDF DOWNLOAD

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Volkswagen Arteon 2021 Repair Manual – PDF DOWNLOAD

FILE DETAILS:

Volkswagen Arteon 2021 Repair Manual – PDF DOWNLOAD 

Language : English
Pages : 9336
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Volkswagen Arteon 2021 Repair Manual – PDF DOWNLOAD 

D3E8046D49A Wheels and Tyres Guide – General Information 1
44 – Wheels, tyres, vehicle geometry 9
1 Instructions on using the guide 9
1 1 Overview 9
1 1 1 Wheels and Tyres Guide – General Information 9
1 1 2 Wheels and Tyres Guide – Vehicle-specific section 9
1 2 General information 9
1 3 Notes 10
1 4 Determining correct wheel and tyre combinations, according to NEDC with tyre package 11
1 4 1 Determining the required tyre package via PR number 11
1 4 2 Determining the required tyre package via version key in the vehicle registration certificate part 1 11
1 5 Determining correct wheel and tyre combinations according to WLTP 12
1 5 1 Vehicle registration certificate part 1 12
1 5 2 COC document, item 0 10 14
1 6 NEDC, WLTP and RDE 14
1 6 1 What are NEDC, WLTP and RDE? 14
1 6 2 What are the differences between WLTP and RDE? 14
1 6 3 Since when are WLTP and RDE valid? 14
1 7 Definition of tyre package 14
1 8 Explanations regarding world regions 15
2 Legislative and technical conditions 17
2 1 Legislative conditions 17
2 1 1 Permissible wheel and tyre combinations in Germany 17
2 1 2 Vehicles with Tyre Pressure Monitoring System 17
2 2 Technical conditions 18
2 3 Load-carrying capacity depending on vehicle speed, winter tyres 18
2 4 Vehicle registration documents since 01 10 2005 20
2 5 COC document (EEC Certificate of Conformity) 21
2 6 EU general type approval number, sales type and sales or trade designation 21
3 Wheel change 24
3 1 Fitting instructions 24
3 2 Protecting wheel centring seat against corrosion 27
3 3 Fitting wheels 27
3 4 Position of anti-theft wheel bolts for steel wheels 28
4 Fitting tyre 30
4 1 Pressing tyre off wheel rim 30
4 2 Removing tyre sealant 31
4 3 Removing tyre from wheel 31
4 3 1 Removing tyres, wheels without and with tyre pressure monitoring 31
4 3 2 Removing tyres, run-flat tyres, ultra-high-performance tyres 33
4 4 Ensuring proper assembly temperature for tyres 35
4 5 Fitting tyre 36
4 5 1 Mounting tyre, wheels without and with tyre pressure monitoring 36
4 5 2 Mounting tyre, run-flat tyres, ultra-high performance tyres 38
4 6 Matching wheel rims and tyres 40
4 7 Checking radial and lateral runout of wheels and tyres 41
4 7 1 Checking radial and lateral runout of wheels and tyres, tolerances 41
4 7 2 Checking radial and lateral runout on wheels and tyres with tyre gauge 42
4 8 Matching wheels and tyres 43
4 9 Balancing wheel 44
4 9 1 Conditions 44
4 9 2 Balancing wheel on stationary wheel balancer 44
4 9 3 Balancing wheel with finish balancer 47
4 9 4 Checking radial and lateral run-out on wheel rim 48
4 10 Tyre sealant disposal 49
5 Tyre Pressure Monitoring System 50
5 1 System description – Tyre Pressure Monitoring System 50
5 1 1 System description – Tyre Pressure Monitoring System with indirect measurement (Tyre Pressure Loss Indicator) 50
5 1 2 System description – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 52
5 1 3 Button behaviour – Tyre Pressure Monitoring System with direct measurement (with tyre pressure sensor) 52
5 1 4 System description – Tyre Pressure Monitoring System, Tyre Pressure Monitoring System (TPMS) with autolocation 53
5 2 Overview of fitting locations – Tyre Pressure Monitoring System 54
5 2 1 Overview of fitting locations – Tyre Pressure Monitoring System (TPMS) with autolocation 54
5 2 2 Overview of fitting locations – Tyre Pressure Monitoring System, Trigger 55
5 2 3 Overview of fitting locations – Tyre Pressure Monitoring System, Autolocation 57
5 3 Assembly overview – tyre pressure sensor 58
5 3 1 Assembly overview – tyre pressure sensor, tyre pressure sensor with valve 58
5 3 2 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 1 60
5 3 3 Assembly overview – tyre pressure sensor, tyre pressure sensor without valve, version 2 62
5 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225- 63
5 4 1 Removing and installing tyre pressure sensor, tyre pressure sensor with valve 63
5 4 2 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (customer service version) 64
5 4 3 Removing and installing tyre pressure sensor, tyre pressure sensor without valve, version 1 (production version) 66
5 4 4 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225-, version 2 69
5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502- 71
5 5 1 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Arteon 2018, Arteon 2021, Arteon Shooting Brake 2021, Passat 2015, Passat Estate 2015, Passat 2019, Passat Estate 2019 72
5 5 2 Removing and installing tyre Tyre Pressure Monitoring System control unit, Passat 2011, Passat Estate 2011 74
5 5 3 Removing and installing Tyre Pressure Monitoring System control unit, CC 2010, CC 2012, Passat CC 2009 74
5 5 4 Removing and installing Tyre Pressure Monitoring System control unit, Phaeton 2003 74
5 5 5 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Touran 2016 74
5 5 6 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2008 75
5 5 7 Removing and installing Tyre Pressure Monitoring System control unit -J502-, Tiguan 2016, Tiguan 2017 (BW2), Tiguan 2021 76
5 5 8 Removing and installing Tyre Pressure Monitoring System control unit, up to model year 2014, Touareg 2010 77
5 5 9 Removing and installing Tyre Pressure Monitoring System control unit, as of model year 2015, Touareg 2015 78
5 5 10 Removing and installing Tyre Pressure Monitoring System control unit, Touareg 2018 79
5 5 11 Removing and installing bracket for Tyre Pressure Monitoring System control unit, Touareg 2015 80
5 6 Removing and installing tyre pressure monitor sender unit in wheel housing 80
5 6 1 Removing and installing sender unit for Tyre Pressure Monitoring System in front left/front right wheel housing -G431/G432-, Touareg 2010, Touareg 2015 80
5 6 2 Removing and installing sender unit for Tyre Pressure Monitoring System in rear left/rear right wheel housing -G433/G434-, Touareg 2010, Touareg 2015 81
5 6 3 Removing and installing sender unit for Tyre Pressure Monitoring System in wheel housing, Phaeton 2003 82
6 Wheel bolts 83
6 1 Wheel bolts, versions 83
6 2 Wheel bolts, anti-theft wheel bolt 85
6 3 Wheel bolts, adapter sets for anti-theft wheel bolts 85
7 Information on tyres 88
7 1 Identification markings on the tyre sidewall 88
7 2 Tyre dimension 90
7 3 Load rating code/load index (LI) 90
7 4 Speed rating code 91
7 5 EU tyre label 91
7 5 1 EU tyre label, summary 91
7 5 2 EU tyre label, objectives 92
7 5 3 EU tyre label, categories 93
7 6 Structure of a radial belted tyre 97
7 6 1 Cross section of a radial belted tyre 97
7 6 2 Run-flat tyres, structure and identification of a SST tyre 98
7 6 3 Run-flat tyres, seal inside technology 100
7 7 Run-flat tyre, SST (Self Supporting Tyre) 103
7 7 1 Run-flat tyres – general information 103
7 7 2 Run-flat tyres, retrofitting/requirements when using run-flat tyres 104
7 7 3 Run-flat tyres, repair work 104
7 8 Tyre storage 104
7 9 Reinforced and Extra Load (XL) tyres 105
7 10 M+S tyres 106
7 11 Winter tyres with speed symbol V 108
7 12 All-season tyres 109
7 13 Optimised rolling resistance tyres 110
7 14 Tyre ageing 110
7 15 Tyres with flange protection 112
7 16 Tyre sizes for vehicles with all-wheel drive 112
7 17 Increase in temperature due to insufficient tyre pressure 112
8 Tyre sealant 114
8 1 Models with breakdown set 114
8 2 Storage life 114
8 3 Disposal 114
9 Information about wheels (rims) 115
9 1 Structure of wheel (rim) 115
9 2 Identification 116
9 3 Composite wheels 117
9 4 Care and maintenance of alloy wheel rims 117
9 5 Restoring alloy wheels 117
9 6 Removing and installing hub cover for alloy wheels with open threaded connection 118
9 7 Renewing trim elements 119
9 7 1 Renewing trim elements, bonded trim elements 119
9 7 2 Renewing trim elements, bolted trim elements 123
9 8 Removing and installing valve 124
9 8 1 Removing and installing valve, description of the valve 124
9 8 2 Removing and installing valve, rubber valve 125
9 8 3 Removing and installing valve, metal valve 126
10 Handling problems 128
10 1 Rolling noise 128
10 1 1 General notes on tyre noise 128
10 1 2 Flat spots (from locking wheels) 129
10 2 Vehicle pulls to one side 130
10 2 1 General information 130
10 2 2 Conicity 130
10 2 3 Remedies when vehicle pulls to one side 132
10 2 4 Strategic rotation of wheels for non-directional tyres 133
10 2 5 Strategic rotation of wheels having unidirectional tyres 134
10 3 Vibration 135
10 3 1 Vibration, causes for vibration 135
10 3 2 Vibration, conducting a road test before balancing wheels 135
10 3 3 Vibration, vibration control system 135
10 4 Eliminating flat spots caused by storage or handling 136
11 Evaluating tyres 138
11 1 Flat spots caused by storage or handling 138
11 2 Undulations 138
11 3 Saw-tooth wear 139
11 4 Flat spots caused by hard braking 139
11 5 Swellings in the tyre sidewall 139
11 6 Cuts 141
11 7 Damage caused by foreign bodies 141
11 8 Stripped profile 142
11 9 Tyre damage due to insufficient tyre pressure 142
11 10 Checking tyres 143
11 11 Damage caused when fitting 144
12 Tyre wear 146
12 1 Factors influencing the service life of tyres 146
12 2 Saw-tooth wear 147
12 3 Wear behaviour of high-speed tyres 148
12 4 Measuring tread depth 148
12 5 One-sided wear 149
12 6 Outer shoulder wear 151
12 7 Diagonal washout 152
12 8 Wear in middle of tyre 153
12 9 Permissible deviation in tread depth 153
13 Overview of components 154
13 1 Assembly overview – wheel 154
14 Snow chains 157
14 1 Assembly and use of snow chains 157
15 Regular and temporary spare wheels, recommended temporary spare tyres 158
15 1 Spare wheel with yellow sticker 158
15 2 Temporary spare wheels and recommended temporary spare tyres 159
15 2 1 Atlas 2017 159
15 2 2 Golf 2013, e-Golf 2014 159
15 2 3 Golf 2017, e-Golf 2017 159
15 2 4 Golf SV 2015 159
15 2 5 Golf Variant 2014 160
15 2 6 Golf Variant 2017 160
15 2 7 Golf 2018 (AU2/BX6) 160
15 2 8 Jetta 2018 160
15 2 9 Taos 2021 161
D3E80473F31 Propshaft and rear final drive 162
00 – Technical data 166
1 Safety information 166
1 1 General safety provisions 166
1 2 Safety precautions when using testers and measuring instruments during a road test 167
1 3 Safety measures when working on vehicles with a start/stop system 168
2 Identification 169
2 1 Identification of final drive 169
2 1 1 Final drive code 02D/0BS/0AY 169
2 1 2 Final drive code 0CQ/0CR/0BR 169
3 Repair instructions 171
3 1 General repair instructions 171
3 1 1 General information 171
3 1 2 Oil 171
3 1 3 Locking devices 171
3 1 4 Bearings 171
3 1 5 Shims 172
3 2 Gaskets and seals 172
3 3 Nuts and bolts 172
4 Technical data 174
4 1 Capacities 174
4 1 1 Capacities, final drive 0BS 174
4 1 2 Capacities, final drive 0AY 174
4 1 3 Capacities, final drive 0CQ 174
4 1 4 Capacities, final drive 0CR 175
4 1 5 Capacities, final drive 0BR 175
5 Electrical components 176
5 1 Overview of fitting locations – electrical components 176
5 1 1 Overview of fitting locations – electrical components, rear final drive “0BS” with all-wheel drive coupling generation IV 176
5 1 2 Overview of fitting locations – electrical components, rear final drive “0CQ/0CR/0AY/0BR” with all-wheel drive coupling generation V and VI 176
39 – Final drive – rear differential 178
1 Final drive 178
1 1 Assembly overview – final drive 178
1 1 1 Assembly overview – final drive 178
1 2 Removing and installing final drive 179
1 2 1 Removing and installing final drive, CC 2012 ►, Passat 2011 ►, Passat Estate 2011 ► 179
1 2 2 Removing and installing final drive, Golf 2013 ►, Golf 2017 ► 189
1 2 3 Removing and installing final drive, Golf Estate 2014 ►, Golf Estate 2017 ► 200
1 2 4 Removing and installing final drive, Passat 2015 ►, Passat Estate 2015 ►, Arteon 2018 ►, Passat 2019 ►, Passat Estate 2019 ► 211
1 2 5 Removing and installing rear final drive, Sharan 2016 ► 221
1 2 6 Removing and installing final drive, Tiguan ► 226
1 2 7 Removing and installing final drive, T-Roc 2018 ►, T-Roc 2022 ►, T-Roc Cabriolet 2022 ► 238
1 2 8 Removing and installing final drive, Tarek Russia 2022 ► 249
2 Assembly mountings 260
2 1 Assembly overview – assembly mountings 260
2 1 1 Assembly overview – subframe, rear final drive 0BS, 0CR, 0AY 260
2 1 2 Assembly overview – subframe, rear final drive 0CQ, 0BR 262
2 2 Removing and installing bonded rubber bush 263
2 2 1 Removing and installing bonded rubber bush, rear final drive 0BS, 0CR, 0AY 263
2 2 2 Removing and installing bonded rubber bush, rear final drove 0CQ, 0BR 265
3 Gear oil 272
3 1 Overview of fitting locations – oil drain and inspection plugs 272
3 1 1 Overview of fitting locations – oil drain and inspection plugs, T-Roc 2018 ►, T-Roc 2022 ►, T-Roc Cabriolet 2022 ► 272
3 1 2 Overview of fitting locations – drain and inspection plugs, Tarek Russia 2022 ► 272
3 2 Checking gear oil level 273
4 Oil seals 276
4 1 Overview of fitting locations – oil seals 276
4 2 Renewing right seal 276
4 2 1 Renewing right oil seal, rear final drive 0BS 276
4 2 2 Renewing right oil seal, rear final drive 0CQ, 0CR, 0AY, 0BR 280
4 3 Renewing left seal 283
4 3 1 Renewing left oil seal, rear final drive 0BS 283
4 3 2 Renewing left oil seal, rear final drive 0CQ, 0CR, 0AY, 0BR 287
4 4 Renewing input shaft seal 290
4 4 1 Renewing input shaft seal 290
5 All-wheel drive coupling 299
5 1 Assembly overview – all-wheel drive coupling 299
5 1 1 Assembly overview – all-wheel drive coupling, generation IV 299
5 1 2 Assembly overview – all-wheel drive coupling, generation V and generation VI 301
5 2 Checking function 303
5 3 Checking fluid level in all-wheel drive coupling 303
5 4 Draining and filling high performance fluid for all-wheel drive coupling 304
5 5 Removing and installing all-wheel drive coupling pump -V181- 307
5 5 1 Removing and installing all-wheel drive coupling pump -V181-, generation IV 307
5 5 2 Removing and installing all-wheel drive coupling pump -V181-, generation V and generation VI 309
5 6 Removing and installing all-wheel drive coupling 313
5 6 1 Removing and installing all-wheel drive coupling, generation IV 313
5 6 2 Removing and installing all-wheel drive coupling, generation V 320
5 6 3 Removing and installing all-wheel drive coupling, generation VI 328
5 7 Removing and installing four-wheel drive control unit -J492- 336
5 7 1 Removing and installing all-wheel drive control unit -J492-, generation IV 336
5 7 2 Removing and installing all-wheel drive control unit -J492-, generation V 339
5 7 3 Removing and installing all-wheel drive control unit -J492-, generation VI 340
6 Propshaft 343
6 1 Assembly overview – propshaft 343
6 1 1 Assembly overview – propshaft, CC 2012 ►, Passat ►, Passat Estate ►, Golf ►, Golf Estate ►, Tiguan ►, Arteon ► 343
6 1 2 Assembly overview – propshaft, Sharan 2016 ► 345
6 1 3 Assembly overview – propshaft, T-Roc 2018 ►, T-Roc 2022 ►, T-Roc Cabriolet 2022 ► 346
6 1 4 Assembly overview – propshaft, Tarek Russia 2022 ► 347
6 2 Removing and installing propshaft 349
6 2 1 Removing and installing propshaft, CC 2012 ►, Passat 2011 ►, Passat Estate 2011 ► 349
6 2 2 Removing and installing propshaft, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ► 354
6 2 3 Removing and installing propshaft, Passat 2015 ►, Passat Estate 2015 ►, Arteon, Passat 2019 ►, Passat Estate 2019 ► 359
6 2 4 Removing and installing propshaft, Sharan 2016 ► 366
6 2 5 Removing and installing propshaft, Tiguan ► 372
6 2 6 Removing and installing propshaft, T-Roc 2018 ►, T-Roc 2022 ►, T-Roc Cabriolet 2022 ► 379
6 2 7 Removing and installing propshaft, Tarek Russia 2022 ► 386
6 3 Removing and installing front flexible coupling 393
6 4 Removing and installing rear flexible coupling 396
D4B802E46CA 4 cyl direct injection engine (1 8 l and 2 0 l 4 V EA 888 gen III turbocharger chain drive) 406
00 – Technical data 414
1 Safety information 414
1 1 Safety precautions when working on the fuel supply system 414
1 2 Safety measures when working on vehicles with start/stop system 414
1 3 Safety precautions when using testers and measuring instruments during a road test 415
1 4 Safety precautions when working on the ignition system 415
1 5 Safety precautions when working on the cooling system 415
1 6 Safety precautions when working on the exhaust system 416
2 Identification 417
2 1 Engine number/engine data 417
3 Repair notes 421
3 1 Rules for cleanliness 421
3 2 Foreign material in engine 421
3 3 Contact corrosion 421
3 4 Routing and attachment of lines 421
3 5 Installing radiators and condensers 422
3 6 Checking vacuum system 422
10 – Removing and installing engine 423
1 Removing and installing engine 423
1 1 Removing engine 423
1 2 Separating engine and gearbox 444
1 2 1 Separating engine and gearbox, vehicles with manual gearbox 444
1 2 2 Separating engine and gearbox, vehicles with 7-speed dual clutch gearbox 447
1 2 3 Separating engine and gearbox, vehicles with 6-speed dual clutch gearbox 449
1 2 4 Separating engine and gearbox, vehicles with automatic gearbox 452
1 3 Securing engine on engine and gearbox support 454
1 4 Installing engine 457
2 Assembly mountings 461
2 1 Assembly overview – assembly mountings 461
2 1 1 Assembly overview – assembly mountings, Golf, Passat, Touran, Tiguan, Arteon 461
2 1 2 Assembly overview – assembly mountings, Sharan 463
2 2 Supporting engine in installation position 465
2 2 1 Supporting engine in installation position, Arteon 465
2 2 2 Supporting engine in installation position, Golf, Touran 469
2 2 3 Supporting engine in installation position, Passat 474
2 2 4 Supporting engine in installation position, Sharan 479
2 2 5 Supporting engine in installation position, Tiguan 482
2 3 Removing and installing engine mounting 486
2 4 Removing and installing gearbox mountings 488
2 5 Removing and installing pendulum support 490
2 5 1 Removing and installing pendulum support, Golf, Passat, Touran, Tiguan, Arteon 490
2 5 2 Removing and installing pendulum support, Sharan 491
2 6 Checking adjustment of assembly mountings 491
2 7 Adjusting assembly mountings 492
3 Engine cover panel 495
3 1 Removing and installing engine cover 495
13 – Crankshaft group 496
1 Cylinder block (pulley end) 496
1 1 Assembly overview – cylinder block (pulley end) 496
1 2 Removing and installing poly V-belts 499
1 3 Removing and installing poly V-belt tensioner 501
1 4 Removing and installing vibration damper 502
1 5 Removing and installing bracket for ancillaries 509
1 6 Removing and installing engine support 512
1 7 Renewing seal for vibration damper 514
2 Cylinder block (gearbox end) 517
2 1 Assembly overview – cylinder block (gearbox end) 517
2 2 Removing and installing flywheel 518
2 3 Removing and installing sealing flange (gearbox end) 520
3 Crankshaft 525
3 1 Assembly overview – crankshaft 525
3 2 Crankshaft dimensions 527
3 3 Allocation of main bearing shells 527
3 4 Renewing needle bearing in crankshaft 529
3 5 Measuring axial clearance of crankshaft 531
3 6 Measuring radial clearance of crankshaft 532
3 7 Removing and installing sender wheel 533
4 Balance shaft 535
4 1 Assembly overview – balance shaft 535
4 2 Removing and installing balance shaft 537
4 2 1 Removing and installing inlet side balance shaft 537
4 2 2 Removing and installing exhaust side balance shaft 540
4 2 3 Renewing oil seal for balance shaft (inlet side) 542
5 Pistons and conrods 544
5 1 Assembly overview – pistons and conrods 544
5 2 Removing and installing pistons 548
5 3 Checking pistons and cylinder bores 550
5 4 Separating parts of new conrod 553
5 5 Checking radial clearance of conrod bearings 553
5 6 Removing and installing oil spray jets 554
15 – Cylinder head, valve gear 556
1 Cylinder head 556
1 1 Assembly overview – cylinder head 556
1 2 Removing and installing cylinder head 559
1 3 Removing and installing vacuum pump 567
1 4 Checking compression 568
2 Timing chain cover 571
2 1 Assembly overview – timing chain cover 571
2 2 Removing and installing timing chain cover 573
2 2 1 Removing and installing upper timing chain cover 573
2 2 2 Removing and installing timing chain cover (bottom) 576
3 Chain drive 582
3 1 Assembly overview – camshaft timing chains 582
3 2 Removing and installing camshaft timing chain 585
3 3 Assembly overview – drive chain for balance shaft 601
3 4 Removing and installing drive chain for balance shaft 604
3 5 Checking timing chain 604
3 6 Checking valve timing 605
4 Valve gear 608
4 1 Assembly overview – valve gear 608
4 2 Removing and installing camshaft 613
4 3 Removing and installing camshaft control valve 1 -N205- 632
4 4 Removing and installing exhaust camshaft control valve 1 -N318- 632
4 5 Removing and installing valve stem oil seals 632
4 5 1 Removing and installing valve stem seals (cylinder head installed) 632
4 5 2 Removing and installing valve stem seals (cylinder head removed) 638
5 Inlet and exhaust valves 644
5 1 Checking valve guides 644
5 2 Checking valves 645
5 3 Valve dimensions 645
17 – Lubrication 646
1 Sump/oil pump 646
1 1 Assembly overview – sump/oil pump 646
1 2 Removing and installing oil level and oil temperature sender -G266- 649
1 3 Removing and installing lower part of sump 650
1 3 1 Removing and installing bottom section of sump, plastic sump 650
1 3 2 Removing and installing bottom section of sump, sheet-metal sump 651
1 4 Removing and installing oil pump 656
1 5 Removing and installing upper part of sump 659
1 6 Engine oil 664
2 Engine oil cooler 665
2 1 Assembly overview – engine oil cooler 665
2 2 Removing and installing engine oil cooler 665
3 Crankcase breather 668
3 1 Assembly overview – crankcase breather system 668
3 2 Removing and installing oil separator 669
4 Oil filter/oil pressure switches 670
4 1 Assembly overview – oil filter 670
4 2 Assembly overview – oil pressure switches/oil pressure control 670
4 3 Removing and installing piston cooling jet control valve -N522- 672
4 4 Removing and installing valve for oil pressure control -N428- 673
4 5 Removing and installing oil pressure switch 674
4 5 1 Removing and installing oil pressure switch -F1- 674
4 5 2 Removing and installing oil pressure switch for reduced oil pressure -F378- 675
4 5 3 Removing and installing stage 3 oil pressure switch -F447- 676
4 6 Checking oil pressure 678
4 6 1 Checking engine oil pressure 678
4 6 2 Checking oil pressure and oil spray jets 680
19 – Cooling 682
1 Cooling system/coolant 682
1 1 Connection diagram – coolant hoses 682
1 1 1 Vehicles with manual gearbox 682
1 1 2 Vehicles with dual clutch gearbox or automatic gearbox 683
1 1 3 Vehicles with dual clutch gearbox, engine code CHHA 685
1 1 4 Vehicles with dual clutch gearbox and auxiliary radiator on right side 687
1 1 5 Vehicles with dual clutch gearbox and auxiliary radiator on right and left sides 689
1 1 6 Sharan with additional heat exchanger 691
1 2 Draining and filling cooling system 692
1 3 Checking cooling system for leaks 701
1 4 Flushing cooling system 705
1 4 1 Flushing cooling system 705
1 4 2 Flushing cooling system, quick reference guide 727
2 Coolant pump/thermostat assembly 729
2 1 Assembly overview – coolant pump/thermostat 729
2 2 Assembly overview – electric coolant pump 731
2 3 Assembly overview – coolant temperature sender 735
2 4 Removing and installing toothed belt for coolant pump 736
2 5 Removing and installing coolant pump 738
2 6 Removing and installing electric coolant pump 741
2 6 1 Removing and installing auxiliary pump for heating -V488- 741
2 7 Removing and installing coolant valves 744
2 7 1 Removing and installing coolant shut-off valve -N82- 744
2 7 2 Removing and installing coolant valve for gearbox -N488-, vehicles with 6-speed dual clutch gearbox 746
2 7 3 Removing and installing coolant valve for gearbox -N488-, vehicles with 7-speed dual clutch gearbox 748
2 7 4 Removing and installing coolant valve for gearbox -N488-, vehicles with automatic gearbox 749
2 8 Removing and installing actuator for engine temperature regulation -N493- 751
2 9 Removing and installing coolant temperature sender -G62- 754
2 10 Removing and installing radiator outlet coolant temperature sender -G83- 755
3 Coolant pipes 757
3 1 Assembly overview – coolant pipes 757
3 2 Removing and installing coolant pipes 757
3 2 1 Removing and installing front coolant pipe 757
3 3 Removing and installing upper coolant pipes 759
4 Radiators/radiator fans 762
4 1 Assembly overview – radiator 762
4 1 1 Assembly overview – radiator, Golf, Passat, Touran, Tiguan, Arteon 762
4 1 2 Assembly overview – radiator/radiator fan, Sharan 764
4 2 Assembly overview – auxiliary radiator 766
4 2 1 Assembly overview – right auxiliary radiator 766
4 2 2 Assembly overview – left auxiliary radiator 767
4 3 Assembly overview – radiator cowl and radiator fans 767
4 3 1 Assembly overview – radiator cowl and radiator fan, Golf, Passat, Arteon 767
4 3 2 Assembly overview – radiator cowl and radiator fan, Sharan 768
4 3 3 Assembly overview – radiator cowl and radiator fan, Touran, Tiguan 769
4 4 Removing and installing radiator 770
4 4 1 Removing and installing radiator, Golf, Passat, Touran, Tiguan, Arteon 770
4 4 2 Removing and installing radiator, Sharan 773
4 5 Removing and installing radiator cowl 778
4 6 Removing and installing radiator fan 781
4 6 1 Removing and installing radiator fan, Golf, Passat, Arteon 781
4 6 2 Removing and installing radiator fan, Sharan 781
4 6 3 Removing and installing radiator fan, Touran, Tiguan 782
4 7 Removing and installing auxiliary radiator 783
4 7 1 Removing and installing right auxiliary radiator 783
4 7 2 Removing and installing left auxiliary radiator 785
21 – Turbocharging/supercharging 788
1 Turbochargers 788
1 1 Assembly overview – turbochargers 788
1 2 Removing and installing turbochargers 794
1 2 1 Removing and installing turbocharger, Golf, Passat, Tiguan, Arteon 794
1 2 2 Removing and installing turbocharger, Sharan, Touran 801
1 3 Removing and installing charge pressure positioner -V465- 806
1 4 Adjusting charge pressure positioner -V465- 807
2 Charge air system 811
2 1 Assembly overview – charge air system 811
2 1 1 Assembly overview – charge air system, Golf, Passat, Touran, Tiguan, Arteon 811
2 1 2 Assembly overview – charge air system, Sharan 813
2 2 Assembly overview – hose connections for charge air system 815
2 3 Removing and installing charge air cooler 815
2 3 1 Removing and installing charge air cooler, Golf, Passat, Touran, Tiguan, Arteon 815
2 3 2 Removing and installing charge air cooler, Sharan 820
2 4 Removing and installing charge pressure sender -G31- 821
2 5 Checking charge air system for leaks 821
2 6 Removing and installing air intake pipe between turbocharger and charge air cooler 824
24 – Mixture preparation – injection 826
1 Injection system 826
1 1 Overview of fitting locations – injection system 826
2 Injectors 838
2 1 Assembly overview – fuel rail with injectors 838
2 1 1 Assembly overview – fuel rail with injectors, direct injection 838
2 1 2 Assembly overview – fuel rail with injectors, indirect injection 840
2 2 Removing and installing fuel rail 840
2 3 Removing and installing injectors 841
2 3 1 Removing and installing injectors, direct injection 841
2 3 2 Removing and installing injectors, indirect injection 846
2 4 Renewing seals on injector 849
2 5 Cleaning injectors 852
3 Air filter 855
3 1 Assembly overview – air filter housing 855
3 2 Removing and installing air filter housing 857
4 Intake manifold 859
4 1 Assembly overview – intake manifold 859
4 2 Removing and installing intake manifold 861
4 3 Removing and installing throttle valve module -GX3- 867
4 4 Cleaning throttle valve module -GX3- 870
5 Senders and sensors 872
5 1 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound, Golf, Passat, Touran, Tiguan 872
5 2 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound, Arteon 873
5 3 Removing and installing fuel pressure sender -G247- 874
5 4 Checking fuel pressure sender -G247- 878
5 4 1 Checking fuel pressure sender -G247- using pressure sensor tester -VAS 6394- 878
5 4 2 Checking fuel pressure sender -G247- using vehicle diagnostic tester (Guided Functions) 881
5 5 Removing and installing fuel pressure sender for low-pressure -G410- 883
5 6 Removing and installing intake manifold sender -GX9- 884
5 7 Removing and installing pressure differential sender for particulate filter -G1037- 885
6 Engine/motor control unit 887
6 1 Removing and installing motor control unit -J623- 887
6 1 1 Removing and installing engine control unit -J623-, Golf, Passat, Touran, Tiguan, Arteon 887
6 1 2 Removing and installing engine control unit -J623-, Sharan 888
6 2 Removing and installing engine control unit -J623- with protective housing 891
6 2 1 Removing and installing engine control unit -J623- with protective housing, Golf, Passat, Touran, Tiguan, Arteon 891
6 2 2 Removing and installing engine control unit -J623- with protective housing, Sharan 894
7 High-pressure pump 900
7 1 Assembly overview – high-pressure pump 900
7 2 Removing and installing high-pressure pump 902
7 3 Removing and installing high-pressure pipe 906
8 Lambda probe 910
8 1 Assembly overview – Lambda probe 910
8 2 Removing and installing Lambda probe 911
8 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 911
8 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 913
26 – Exhaust system 915
1 Exhaust pipes/silencers 915
1 1 Assembly overview – silencers 915
1 1 1 Assembly overview – silencer, Golf, front-wheel drive 915
1 1 2 Assembly overview – silencers, titanium version 917
1 1 3 Assembly overview – silencers, Golf CJSB; Passat CJXA, DNUA; Arteon 919
1 1 4 Assembly overview – silencers, Passat with engine codes CJSA, CJSC 921
1 1 5 Assembly overview – silencer, Passat CHHB, CXDA 923
1 1 6 Assembly overview – silencers, Sharan 925
1 1 7 Assembly overview – silencers, Touran 925
1 1 8 Assembly overview – silencers, Tiguan 927
1 2 Removing and installing silencers 928
1 2 1 Removing and installing silencer, Golf, front-wheel drive 928
1 2 2 Removing and installing silencers, Golf CJSB; Passat CJXA, DNUA; Arteon 930
1 2 3 Removing and installing silencer, Passat with engine codes CJSA, CJSC 931
1 2 4 Removing and installing silencer, Passat CHHB, CXDA 934
1 2 5 Removing and installing silencer, Sharan 936
1 2 6 Removing and installing silencer, Touran 936
1 2 7 Removing and installing silencer, Tiguan 937
1 3 Separating exhaust pipes/silencers 939
1 3 1 Separating exhaust pipes/silencers, Golf, front-wheel drive 939
1 3 2 Separating exhaust pipes silencers, Passat with engine codes CJSA, CJSC 940
1 3 3 Separating exhaust pipes and silencers, Passat CHHB, CJXA, CXDA, DNUA; Golf CJSB; Arteon 942
1 3 4 Separating exhaust pipes/silencers, Touran 945
1 4 Stress-free alignment of exhaust system 946
1 5 Checking exhaust system for leaks 947
2 Emission control system 948
2 1 Assembly overview – emission control system 948
2 1 1 Assembly overview – emission control, Golf, Passat, Touran, Arteon 948
2 1 2 Assembly overview – exhaust gas treatment, Sharan 951
2 1 3 Assembly overview – exhaust gas treatment, Tiguan 952
2 1 4 Assembly overview – emission control, vehicles with particulate filter and front-wheel drive 957
2 1 5 Assembly overview – emission control, vehicles with particulate filter and all-wheel drive 960
2 2 Assembly overview – bracket and pipes for pressure differential sender for particulate filter -G1037- 963
2 3 Removing and installing catalytic converter 964
2 3 1 Removing and installing catalytic converter, vehicles without particulate filter 964
2 3 2 Removing and installing catalytic converter, vehicles with particulate filter and front-wheel drive 972
2 3 3 Removing and installing catalytic converter, vehicles with particulate filter and all-wheel drive 976
2 4 Removing and installing holder of pressure differential sender for particulate filter -G1037- 981
2 5 Removing and installing exhaust flap control unit -J883/J945-, Passat CJXA, Arteon 982
3 Exhaust gas temperature regulation 983
3 1 Assembly overview – exhaust gas temperature regulation 983
3 2 Removing and installing parts of exhaust gas temperature regulation 984
3 2 1 Removing and installing exhaust gas temperature sender, vehicles with front-wheel drive 984
3 2 2 Removing and installing exhaust gas temperature sender, vehicles with all-wheel drive 986
4 Secondary air system 989
4 1 Assembly overview – secondary air system 989
4 2 Removing and installing secondary air pump motor -V101- 990
4 3 Renewing stop buffer for secondary air pump 990
4 4 Removing and installing secondary air inlet valve -N112- 991
28 – Ignition system 993
1 Ignition system 993
1 1 Assembly overview – ignition system 993
1 2 Removing and installing ignition coils with output stage 995
1 3 Removing and installing knock sensor 1 -G61- 997
1 4 Removing and installing Hall sender 999
1 4 1 Removing and installing Hall sender -G40- 999
1 4 2 Removing and installing Hall sender 3 -G300- 999
1 5 Removing and installing engine speed sender -G28- 1000
D4B804A2FD3 Brake system 1002
00 – Technical data 1006
1 Safety information 1006
1 1 Safety precautions when using testers and measuring instruments during a road test 1006
2 Identification 1007
2 1 Allocation of PR number – brakes 1007
2 1 1 Front brakes, Passat, Passat Estate 1007
2 1 2 Front brake, Arteon 1007
2 1 3 Rear brakes, Passat, Passat Estate 1008
2 1 4 Rear brakes, Arteon 1008
3 Technical data 1010
3 1 Technical data for brakes 1010
3 1 1 Brake master cylinder and brake servo 1010
4 Brake test 1013
4 1 General information 1013
4 2 Checking vehicles with front-wheel drive 1013
4 3 Checking vehicles with all-wheel drive 1013
4 3 1 On a regulated roller dynamometer with counter-rotating rollers for four-wheel drive vehicles 1013
4 3 2 Without roller dynamometer for four-wheel drive vehicles 1014
4 4 Checking parking brake 1014
4 4 1 Checking electromechanical parking brake, vehicles with front-wheel drive 1014
4 4 2 Checking electromechanical parking brake, vehicles with all-wheel drive 1015
45 – Anti-lock brake system 1016
1 General information 1016
1 1 Repair instructions for repair work on ABS 1016
2 Overview of fitting locations 1019
2 1 Overview of fitting locations – ABS/ESP 1019
3 Control unit and hydraulic unit 1021
3 1 Assembly overview – control unit and hydraulic unit 1021
3 1 1 Assembly overview – control unit and hydraulic unit, LHD 1021
3 1 2 Assembly overview – control unit and hydraulic unit, right-hand drive 1023
3 2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55- 1025
3 2 1 Removing and installing control unit and hydraulic unit, left-hand drive, petrol engines 1025
3 2 2 Removing and installing control unit and hydraulic unit, left-hand drive vehicles with diesel engine 1029
3 2 3 Removing and installing control unit and hydraulic unit, right-hand drive 1036
3 2 4 Removing and installing control unit and hydraulic unit, LHD vehicles, bi-turbo diesel engine 1040
3 3 Connecting brake lines to hydraulic unit 1047
3 3 1 Connecting brake lines to hydraulic unit, LHD 1047
3 3 2 Connecting brake lines to hydraulic unit, RHD 1048
3 4 Separating control unit from hydraulic unit 1049
3 5 Fitting control unit to hydraulic unit 1050
4 Sensors 1052
4 1 Assembly overview – speed sensor on front axle 1052
4 2 Assembly overview – speed sensor on rear axle 1053
4 2 1 Assembly overview – speed sensor on rear axle, front-wheel drive 1053
4 2 2 Assembly overview – speed sensor on rear axle, all-wheel drive 1054
4 3 Removing and installing speed sensors on front axle -G45-/-G47- 1054
4 4 Removing and installing speed sensors on rear axle -G44-/-G46- 1055
4 4 1 Removing and installing speed sensor on rear axle -G44-/-G46-, vehicles with front-wheel drive 1055
4 4 2 Removing and installing speed sensor on rear axle -G44-/-G46-, vehicles with all-wheel drive 1056
4 5 Checking ABS sensor ring 1056
4 6 Removing and installing ESP sensor unit -G419- 1057
4 7 Removing and installing steering angle sender -G85- 1058
46 – Brakes – mechanism 1059
1 Front brake 1059
1 1 Assembly overview – front brake 1059
1 1 1 Assembly overview – front brake 1059
1 2 Removing and installing brake pads 1061
1 2 1 Removing and installing brake pads, front brakes 1061
1 3 Removing and installing brake caliper 1064
1 3 1 Removing and installing brake caliper 1064
2 Rear brake 1066
2 1 Assembly overview – rear brakes 1066
2 2 Removing and installing brake pads 1068
2 3 Removing and installing brake caliper 1072
3 Parking brake 1077
3 1 Overview of fitting locations – parking brake 1077
3 2 Removing and installing control unit for electromechanical parking brake -J540- 1078
3 3 Removing and installing parking brake motor -V282-/-V283- 1078
4 Brake pedal 1081
4 1 Assembly overview – brake pedal 1081
4 1 1 Assembly overview – brake pedal, left-hand drive 1081
4 1 2 Assembly overview – brake pedal, right-hand drive 1083
4 2 Separating brake pedal from brake servo 1084
4 3 Connecting brake pedal to brake servo 1085
4 4 Removing and installing brake pedal 1085
4 4 1 Removing and installing brake pedal, left-hand drive vehicles 1085
4 5 Removing and installing mounting bracket 1086
4 5 1 Removing and installing mounting bracket, left-hand drive 1086
4 5 2 Removing and installing mounting bracket, RHD 1088
47 – Brakes – hydraulics 1091
1 Front brake caliper 1091
1 1 Assembly overview – front brake caliper 1091
1 1 1 Assembly overview – brake caliper PC57 and C60 1091
1 2 Removing and installing brake caliper piston 1092
1 2 1 Removing and installing PC57 brake caliper piston 1092
2 Rear brake caliper 1095
2 1 Assembly overview – rear brake caliper 1095
2 2 Removing and installing protective cap 1095
3 Brake servo and brake master cylinder 1099
3 1 Assembly overview – brake servo/brake master cylinder 1099
3 1 1 Assembly overview – brake servo/brake master cylinder, left-hand drive vehicles 1099
3 1 2 Assembly overview – brake servo/brake master cylinder, right-hand drive 1101
3 1 3 Assembly overview – electromechanical brake servo/brake master cylinder, left-hand drive vehicles 1104
3 1 4 Assembly overview – electromechanical brake servo/brake master cylinder, right-hand drive vehicles 1105
3 2 Removing and installing brake light switch 1107
3 2 1 Removing and installing brake light switch, LHD 1107
3 2 2 Removing and installing brake light switch, right-hand drive 1108
3 3 Removing and installing brake master cylinder 1109
3 3 1 Removing and installing brake master cylinder, left-hand drive 1109
3 3 2 Removing and installing brake master cylinder, RHD 1113
3 3 3 Removing and installing brake master cylinder, LHD vehicles, bi-turbo diesel engine 1120
3 3 4 Removing and installing brake master cylinder, e-brake servo, left-hand drive vehicles 1123
3 3 5 Removing and installing brake master cylinder, electromechanical brake servo, right-hand drive vehicles 1128
3 4 Removing and installing brake servo 1134
3 4 1 Removing and installing brake servo, LHD vehicles, petrol engine 1134
3 4 2 Removing and installing brake servo, left-hand drive vehicles with diesel engine 1140
3 4 3 Removing and installing brake servo, LHD vehicles, bi-turbo diesel engine 1146
3 4 4 Removing and installing brake servo, right-hand drive vehicles with petrol engine 1151
3 4 5 Removing and installing brake servo, right-hand drive with diesel engine 1155
3 4 6 Removing and installing electromechanical brake servo, left-hand drive vehicles 1157
3 4 7 Removing and installing electromechanical brake servo, right-hand drive vehicles 1159
4 Vacuum system 1163
4 1 Assembly overview – vacuum pump 1163
4 1 1 Assembly overview – vacuum pump, vehicles with diesel engine 1163
4 1 2 Assembly overview – vacuum pump, vehicles with 1 8 l and 2 0 l petrol engine 1163
4 1 3 Assembly overview of vacuum pump for brakes -V192-, vehicles with 1 4 l petrol engine 1164
4 1 4 Assembly overview of vacuum pump for brakes -V192-, vehicles with 1 5 l petrol engine 1165
4 2 Checking non-return valve 1167
4 3 Removing and installing vacuum sender -G608- 1167
4 4 Removing and installing electric vacuum pump 1167
4 5 Checking vacuum system 1168
4 5 1 Connecting vacuum gauge for brake servo -VAS 6721- 1169
4 5 2 Checking vacuum generation 1170
4 5 3 Checking for leaks 1170
5 Brake lines 1173
5 1 Repairing brake lines 1173
5 1 1 Assembly overview – flanging tool 1175
5 1 2 Work instructions 1175
6 Hydraulic system 1178
6 1 General notes on brake fluid 1178
6 1 1 Changing brake fluid 1178
6 2 Pre-bleeding hydraulic system 1178
6 3 Bleeding hydraulic system following standard procedure 1180
6 4 Subsequent bleeding of hydraulic system 1181
6 5 Testing for leaks 1182
D4B804A2FD4 Fuel supply system petrol engines 1183
00 – Technical data 1187
1 Safety information 1187
1 1 Safety regulations for working on fuel supply 1187
1 2 Safety precautions when using testers and measuring instruments during a road test 1187
1 3 Safety measures when working on vehicles with a start/stop system 1188
2 Identification 1189
2 1 Engine number/engine data 1189
3 General information 1191
3 1 Rules for cleanliness when working on auxiliary heater and fuel system 1191
4 Repair instructions 1192
4 1 Routing and attachment of lines 1192
4 2 General repair instructions 1192
20 – Fuel supply system 1193
1 Fuel 1193
1 1 Assembly overview – fuel tank 1193
1 1 1 Assembly overview – fuel tank, Passat and Arteon with front-wheel drive 1193
1 1 2 Assembly overview – fuel tank, Tiguan with front-wheel drive 1195
1 1 3 Assembly overview – fuel tank, vehicles with four-wheel drive 1197
1 1 4 Renewing seal for cap 1199
1 2 Removing and installing fuel tank 1200
1 2 1 Removing and installing fuel tank – Passat and Arteon with front-wheel drive 1200
1 2 2 Removing and installing fuel tank – Tiguan with front-wheel drive 1206
1 2 3 Removing and installing fuel tank – vehicles with four-wheel drive 1213
1 2 4 Checking earth cable on filler neck from fuel tank 1222
1 3 Emptying fuel tank 1223
1 3 1 Emptying fuel tank when fuel pump is intact 1223
1 3 2 Emptying fuel tank if more than 3/4 full, Passat and Arteon 1226
1 3 3 Emptying fuel tank if more than 3/4 full, Tiguan 1228
1 3 4 Emptying fuel tank less than 3/4 full, vehicles with front-wheel drive 1230
1 3 5 Emptying fuel tank less than 3/4 full, vehicles with four-wheel drive 1233
2 Fuel delivery unit, fuel gauge sender 1238
2 1 Assembly overview – fuel delivery unit/fuel gauge sender 1238
2 1 1 Assembly overview – fuel delivery unit/fuel gauge sender, vehicles with front-wheel drive 1238
2 1 2 Assembly overview – fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive 1240
2 1 3 Assembly overview – fuel delivery unit/fuel gauge sender, vehicles with auxiliary heater 1243
2 1 4 Assembly overview – fuel delivery unit/left fuel gauge sender 1245
2 2 Removing and installing fuel delivery unit, fuel gauge sender 1247
2 2 1 Removing and installing fuel delivery unit/fuel gauge sender, vehicles with front-wheel drive 1247
2 2 2 Removing and installing fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive 1252
2 2 3 Removing and installing fuel line for auxiliary/supplementary heater 1258
2 3 Removing and installing fuel gauge sender -G- 1260
2 3 1 Removing and installing fuel gauge sender -G-, vehicles with front-wheel drive 1260
2 3 2 Removing and installing fuel gauge sender -G-, vehicles with four-wheel drive 1261
2 4 Removing and installing fuel gauge sender 2 -G169- 1262
2 5 Removing and installing assembly opening cover 1267
2 5 1 Removing and installing assembly opening cover, Passat and Arteon 1267
2 5 2 Removing and installing assembly opening cover, Tiguan 1268
3 Plug-in connectors 1270
3 1 Separating plug-in connectors 1270
4 Fuel filter 1277
5 Activated charcoal filter system 1278
5 1 Connection diagram – activated charcoal filter system 1278
5 1 1 Connection diagram – activated charcoal filter system, vehicles with fuel tank leak diagnosis 1278
5 1 2 Connection diagram – activated charcoal filter system, engine compartment, vehicles with 1 5 l engine from model year 2020 1279
5 1 3 Connection diagram – activated charcoal filter system, engine compartment, vehicles with 1 4 l engine from model year 2020 1280
5 2 Assembly overview – activated charcoal filter system 1281
5 2 1 Assembly overview – activated charcoal filter system with fuel tank leak diagnosis 1281
5 2 2 Assembly overview – activated charcoal filter without fuel tank leak diagnosis 1282
5 3 Removing and installing activated charcoal filter 1284
5 3 1 Removing and installing activated charcoal filter, vehicles with fuel tank leak diagnosis 1284
5 3 2 Removing and installing air filter for activated charcoal filter system, vehicles with fuel tank leak detection 1285
5 3 3 Removing and installing activated charcoal filter, vehicles without fuel tank leak diagnosis 1286
5 4 Removing and installing fuel system diagnosis pump 1288
5 5 Checking fuel tank breather, vehicles without fuel tank leak diagnosis 1289
5 6 Checking fuel system for leaks, vehicles with fuel tank leak diagnosis 1295
5 6 1 Checking fuel system for leaks, with exhaust-smoke tester -KLI 9210- 1295
5 6 2 Checking fuel system for leaks, with exhaust-smoke tester -VAS 523 005- 1298
6 Accelerator pedal 1307
6 1 Assembly overview – accelerator module 1307
6 2 Removing and installing accelerator pedal module -GX2- 1307
7 Fuel pump 1309
7 1 Checking fuel system pressurisation pump -G6-, EA888evo 1309
7 2 Checking fuel system pressurisation pump -G6-, EA211, EA888 1317
7 2 1 Checking fuel pressure in engine compartment 1317
7 2 2 Checking pressure at fuel delivery unit -GX1- 1319
7 2 3 Checking fuel delivery rate of fuel system pressurisation pump -G6- in engine compartment 1321
7 2 4 Checking fuel delivery rate at fuel delivery unit -GX1- 1324
7 2 5 Connecting test instrument adapter for voltage measurement at fuel delivery unit 1327
7 2 6 Connecting remote control 1330
7 3 Removing and installing suction-jet pump 1333
7 4 Removing and installing fuel pump control unit -J538- 1335
7 4 1 Removing and installing control unit for fuel pump -J538-, Passat and Arteon 1335
7 4 2 Removing and installing fuel pump control unit -J538-, Tiguan 1336
7 5 Checking suction-jet pump 1337
8 Senders and sensors 1339
8 1 Assembly overview – fuel quality sender 1339
8 2 Removing and installing fuel quality sender -G446- 1340
9 Fuel lines 1341
9 1 Removing and installing fuel lines 1341
D4B804A2FD5 Fuel supply system diesel engines 1347
00 – Technical data 1351
1 Safety information 1351
1 1 Safety regulations for working on fuel supply 1351
1 2 Safety measures when working on vehicles with start/stop system 1352
1 3 Safety precautions when using testers and measuring instruments during a road test 1352
1 4 Safety precautions when working on SCR system 1352
2 Identification 1354
2 1 Engine number/engine data 1354
3 General information 1355
3 1 Rules for cleanliness when working on auxiliary heater and fuel system 1355
4 Repair instructions 1356
4 1 Rules for cleanliness 1356
4 2 Foreign bodies in engine 1356
4 3 Contact corrosion 1356
4 4 Routing and attachment of lines 1357
4 5 Fitting radiator and condensers 1357
20 – Fuel supply system 1358
1 Procedure in event of misfuelling 1358
1 1 Procedure in event of misfuelling 1358
1 1 1 Step 1, engine was started with incorrect fuel 1358
1 1 2 Step 2, engine was not started with incorrect fuel 1360
1 1 3 Step 3, there are metal particles in fuel delivery unit and fuel tank 1362
1 1 4 Step 4, there are no metal particles in fuel delivery unit or fuel tank 1363
1 1 5 Step 5, there are metal particles in high-pressure pump 1365
1 1 6 Step 6, there are no metal particles in high-pressure pump 1365
2 Fuel 1367
2 1 Assembly overview – fuel tank 1367
2 1 1 Assembly overview – fuel tank, Passat and Arteon with front-wheel drive 1367
2 1 2 Assembly overview – fuel tank, Tiguan with front-wheel drive 1369
2 1 3 Assembly overview – fuel tank, vehicles with four-wheel drive 1371
2 1 4 Renewing seal for cap 1373
2 2 Removing and installing fuel tank 1374
2 2 1 Removing and installing fuel tank – Passat and Arteon with front-wheel drive 1374
2 2 2 Removing and installing fuel tank – Tiguan with front-wheel drive 1380
2 2 3 Removing and installing fuel tank – vehicles with four-wheel drive 1388
2 3 Emptying fuel tank 1396
2 3 1 Emptying fuel tank when fuel pump is intact 1396
2 3 2 Emptying fuel tank if more than 3/4 full, Passat and Arteon 1398
2 3 3 Emptying fuel tank if more than 3/4 full, Tiguan 1400
2 3 4 Emptying fuel tank less than 3/4 full, vehicles with front-wheel drive 1402
2 3 5 Emptying fuel tank less than 3/4 full, vehicles with four-wheel drive 1404
2 4 Removing and installing misfuelling prevention device 1409
2 4 1 Removing and installing misfuelling prevention device, plastic cap 1409
2 4 2 Removing and installing misfuelling prevention device, metal cap 1412
2 5 Deactivating misfuelling prevention device 1413
2 5 1 Deactivating the misfuelling prevention device, plastic cap 1413
2 5 2 Deactivating the misfuelling prevention device, metal cap 1414
3 Fuel delivery unit, fuel gauge sender 1415
3 1 Assembly overview – fuel delivery unit/fuel gauge sender 1415
3 1 1 Assembly overview – fuel delivery unit/fuel gauge sender, vehicles with front-wheel drive 1415
3 1 2 Assembly overview – fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive 1418
3 1 3 Assembly overview- fuel gauge sender, left, all-wheel drive 1421
3 2 Removing and installing fuel delivery unit, fuel gauge sender 1423
3 2 1 Removing and installing fuel delivery unit/fuel gauge sender, vehicles with front-wheel drive 1423
3 2 2 Removing and installing fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive 1428
3 3 Removing and installing fuel gauge sender -G- 1433
3 3 1 Removing and installing fuel gauge sender -G-, vehicles with front-wheel drive 1433
3 3 2 Removing and installing fuel gauge sender -G-, vehicles with four-wheel drive 1434
3 4 Removing and installing fuel gauge sender 2 -G169- 1434
3 5 Removing and installing assembly opening cover 1439
3 5 1 Removing and installing assembly opening cover, Passat and Arteon 1439
3 5 2 Removing and installing assembly opening cover, Tiguan 1440
4 Plug-in connectors 1441
4 1 Separating plug-in connectors 1441
5 Fuel filter 1448
5 1 Assembly overview – fuel filter 1448
5 1 1 Assembly overview – fuel filter 1448
5 1 2 Assembly overview – fuel filter, vehicles with water separator sender -G63- 1448
5 2 Removing and installing fuel filter 1449
5 3 Fuel hoses in the engine compartment 1453
6 Accelerator pedal 1455
6 1 Assembly overview – accelerator module 1455
6 2 Removing and installing accelerator pedal module -GX2- 1455
7 Fuel supply 1457
7 1 Checking fuel system pressurisation pump -G6- 1457
7 1 1 Checking fuel pressure 1457
7 1 2 Checking fuel delivery rate 1465
7 1 3 Checking low pressure fuel system, EA288evo 1474
7 2 Removing and installing suction-jet pump 1478
7 3 Removing and installing fuel pump control unit -J538- 1483
7 3 1 Removing and installing control unit for fuel pump -J538-, Passat and Arteon 1483
7 3 2 Removing and installing fuel pump control unit -J538-, Tiguan 1484
7 4 Checking suction-jet pump 1485
8 Fuel lines 1487
8 1 Removing and installing fuel lines 1487
8 2 Removing and installing fuel line for auxiliary/supplementary heater 1492
9 Senders and sensors 1495
9 1 Removing and installing water separator sender -G63- 1495
D4B804A2FDB 4 cylinder common rail (1 6 l and 2 0 l 4 V turbocharger EA 288) 1496
00 – Technical data 1504
1 Safety information 1504
1 1 Safety regulations for working on fuel supply 1504
1 2 Safety measures when working on vehicles with start/stop system 1505
1 3 Safety precautions when using testers and measuring instruments during a road test 1505
1 4 Safety precautions when working on the cooling system 1505
1 5 Safety precautions when working on SCR system 1505
1 6 Safety precautions when working on exhaust system 1506
2 Identification 1508
2 1 Engine number/engine data 1508
3 Repair instructions 1511
3 1 Rules for cleanliness 1511
3 2 Foreign bodies in engine 1511
3 3 Contact corrosion 1511
3 4 Routing and attachment of lines 1512
3 5 Fitting radiator and condensers 1512
4 Technical data 1514
4 1 Coolant 1515
10 – Removing and installing engine 1517
1 Removing and installing engine 1517
1 1 Removing engine 1517
1 2 Separating engine and gearbox 1530
1 2 1 Separating engine and gearbox, vehicles with manual gearbox 1530
1 2 2 Separating engine and gearbox, vehicles with dual clutch gearbox 1532
1 3 Securing engine on engine and gearbox support 1534
1 4 Installing engine 1536
2 Assembly mountings 1542
2 1 Assembly overview – assembly mountings 1542
2 2 Removing and installing engine mounting 1544
2 3 Removing and installing gearbox mounting 1545
2 4 Removing and installing pendulum support 1547
2 5 Supporting engine in installation position 1549
2 5 1 Supporting engine in installation position, Passat 1549
2 5 2 Supporting engine in installation position, Arteon 1553
2 6 Adjusting assembly mountings 1559
2 7 Checking adjustment of assembly mountings 1561
3 Engine cover panel 1562
3 1 Removing and installing engine cover 1562
13 – Crankshaft group 1563
1 Cylinder block (pulley end) 1563
1 1 Assembly overview – cylinder block (pulley end) 1563
1 2 Assembly overview – sealing flange, belt pulley end 1565
1 3 Removing and installing poly-V belt 1567
1 4 Removing and installing tensioner for poly V-belt 1568
1 5 Removing and installing vibration damper 1569
1 6 Removing and installing bracket for ancillaries 1570
1 7 Removing and installing engine support 1572
1 8 Removing and installing sealing flange on pulley end 1573
1 9 Renewing caps in cylinder block (pulley end) 1576
2 Cylinder block, gearbox end 1578
2 1 Assembly overview – cylinder block, gearbox end 1578
2 2 Removing and installing flywheel 1579
2 3 Removing and installing sealing flange on gearbox side 1582
2 3 1 Removing and installing sealing flange, crankshaft flange with 6 bolting points 1582
2 3 2 Removing and installing sealing flange, crankshaft flange with 8 bolting points 1592
2 4 Renewing caps in cylinder block (gearbox end) 1602
3 Crankshaft 1604
3 1 Assembly overview – crankshaft 1604
3 2 Crankshaft dimensions 1606
3 3 Renewing needle bearing in crankshaft 1606
3 4 Measuring axial clearance of crankshaft 1609
4 Pistons and conrods 1611
4 1 Assembly overview – pistons and conrods 1611
4 2 Removing and installing pistons 1615
4 3 Measuring piston projection at TDC 1616
4 4 Checking pistons and cylinder bores 1619
4 5 Separating new conrod 1621
4 6 Checking radial clearance of conrods 1622
15 – Cylinder head, valve gear 1623
1 Cylinder head 1623
1 1 Assembly overview – cylinder head 1623
1 2 Assembly overview – cylinder head cover 1627
1 3 Removing and installing cylinder head 1629
1 4 Removing and installing cylinder head cover 1640
1 5 Removing and installing injector seals 1642
1 6 Removing and installing camshaft housing 1643
1 7 Checking compression 1649
2 Toothed belt drive 1652
2 1 Assembly overview – toothed belt cover 1652
2 2 Assembly overview – toothed belt 1652
2 3 Removing and installing toothed belt guard 1654
2 3 1 Removing and installing upper toothed belt guard, vehicles without SCR system 1654
2 3 2 Removing and installing upper toothed belt guard, vehicles with SCR 1656
2 3 3 Removing and installing lower toothed belt guard 1659
2 4 Removing and installing toothed belt 1661
2 5 Removing toothed belt from camshaft 1675
3 Valve gear 1680
3 1 Assembly overview – valve gear 1680
3 2 Measuring axial play of camshaft 1684
3 3 Removing and installing camshaft oil seal 1685
3 4 Removing and installing camshaft adjuster 1687
3 4 1 Removing and installing control valve for the camshaft adjuster 1691
3 5 Removing and installing camshaft control valve 1 -N205- 1694
3 6 Checking hydraulic compensation elements 1694
3 7 Removing and installing valve stem oil seals 1695
3 7 1 Removing and installing valve stem seals (cylinder head installed) 1695
3 7 2 Removing and installing valve stem seals (cylinder head removed) 1700
4 Inlet and exhaust valves 1706
4 1 Checking valve guides 1706
4 2 Checking valves 1707
4 3 Valve dimensions 1707
17 – Lubrication 1708
1 Sump, oil pump 1708
1 1 Assembly overview – sump/oil pump 1708
1 1 1 Assembly overview – sump/oil pump 1708
1 1 2 Assembly overview – sump/oil pump, two-piece sump 1711
1 2 Engine oil: 1715
1 3 Removing and installing oil sump 1716
1 4 Removing and installing lower part of sump 1720
1 5 Removing and installing upper part of sump 1724
1 6 Removing and installing oil pump 1728
1 7 Removing and installing oil level and oil temperature sender -G266- 1729
1 7 1 Removing and installing oil level and oil temperature sender -G266- 1729
1 7 2 Removing and installing oil level and oil temperature sender -G266-, vehicles with two-piece sump 1730
2 Engine oil cooler 1732
3 Oil filter, oil pressure switch 1733
3 1 Assembly overview – oil filter housing, oil pressure switch 1733
3 2 Removing and installing oil pressure switch -F1- 1735
3 3 Removing and installing oil pressure switch for reduced oil pressure -F378- 1737
3 4 Checking oil pressure 1739
3 5 Removing and installing oil filter housing 1739
3 6 Removing and installing oil pressure regulating valve -N428- 1743
4 Oil circuit 1744
4 1 Removing and installing oil supply line 1744
4 2 Removing and installing oil return line for turbocharger 1745
19 – Cooling 1747
1 Cooling system/coolant 1747
1 1 Connection diagram – coolant hoses 1747
1 1 1 Connection diagram – coolant hoses, vehicles with 1 6 l and 2 0 l engine 1747
1 1 2 Connection diagram – coolant hoses, vehicles with 2 0 l engine, water-cooled turbocharger and SCR system 1750
1 1 3 Coolant hose schematic diagram, vehicles with SCR system 1752
1 2 Checking cooling system for leaks 1754
1 3 Draining coolant 1757
1 4 Filling with coolant 1760
1 4 1 Filling with coolant without electric vacuum pump 1760
1 4 2 Filling coolant with electric vacuum pump -VAS 6096/2- 1765
1 5 Checking filling quality of cooling system 1773
1 6 Checking electric vacuum pump -VAS 6096/2- 1775
1 7 Flushing cooling system 1776
1 7 1 Flushing cooling system, quick reference guide 1798
2 Coolant pump, regulation of cooling system 1800
2 1 Assembly overview – coolant pump, thermostat 1800
2 1 1 Assembly overview – coolant pump/thermostat, version 1 1800
2 1 2 Assembly overview – coolant pump/thermostat, version 2 1802
2 2 Assembly overview – electric coolant pump 1804
2 2 1 Assembly overview – charge air cooling pump -V188- and auxiliary pump for heating -V488-, version 1 1804
2 2 2 Assembly overview – charge air cooling pump -V188-, version 2 1805
2 2 3 Assembly overview – auxiliary pump for heating -V488-, version 2 1806
2 2 4 Assembly overview – charge air cooling pump -V188-, version 3 1807
2 2 5 Assembly overview – auxiliary pump for heating -V488-, version 3 1808
2 2 6 Assembly overview – charge air cooling pump -V188-, version 4 1809
2 3 Assembly overview – coolant temperature sender 1810
2 4 Removing and installing electric coolant pump 1812
2 4 1 Removing and installing charge air cooling pump -V188-, versions 1 and 2 1812
2 4 2 Removing and installing auxiliary pump for heating -V488-, version 1 1814
2 4 3 Removing and installing charge air cooling pump -V188-, version 3 1817
2 4 4 Removing and installing auxiliary pump for heating -V488-, version 2 1820
2 4 5 Removing and installing auxiliary pump for heating -V488-, version 3 1823
2 4 6 Removing and installing charge air cooling pump -V188-, version 4 1827
2 5 Removing and installing coolant pump 1830
2 6 Removing and installing thermostat 1831
2 6 1 Removing and installing thermostat, version 1 1831
2 6 2 Removing and installing thermostat, version 2 1832
2 7 Checking thermostat 1835
2 8 Removing and installing coolant valve for cylinder head -N489- 1835
2 9 Removing and installing coolant temperature sender -G62- 1836
3 Coolant pipes 1838
3 1 Assembly overview – coolant pipes 1838
3 2 Removing and installing coolant pipes 1840
3 2 1 Removing and installing coolant pipes (top front) 1840
3 2 2 Removing and installing lower front coolant pipe 1841
3 2 3 Removing and installing coolant pipe (front left) 1843
3 2 4 Removing and installing front right coolant pipe 1845
3 2 5 Removing and installing left coolant pipes 1847
3 2 6 Removing and installing rear coolant pipe 1849
3 2 7 Removing and installing rear right coolant pipe 1851
4 Radiator, radiator fan 1856
4 1 Assembly overview – radiator/radiator fan 1856
4 1 1 Assembly overview – radiator, version 1 1856
4 1 2 Assembly overview – radiator, version 2 1858
4 1 3 Connecting coolant hose with plug-in connector 1859
4 1 4 Coolant hoses with pretensioned spring-type clips 1859
4 2 Assembly overview – radiator cowl and radiator fan 1860
4 2 1 Assembly overview – radiator cowl and radiator fan -V7- 1860
4 2 2 Assembly overview – radiator cowl, radiator fan -V7- and radiator fan 2 -V177- 1861
4 3 Assembly overview – radiator blind 1862
4 4 Removing and installing radiator 1865
4 5 Removing and installing water radiator for charge air cooling circuit 1868
4 6 Removing and installing radiator cowl 1872
4 7 Removing and installing radiator fan 1875
4 7 1 Removing and installing radiator fan -V7- 1875
4 7 2 Removing and installing radiator fan -V7- and radiator fan 2 -V177- 1875
4 8 Removing and installing radiator blind 1876
4 9 Removing and installing radiator blind control motor -V544- 1878
21 – Turbocharging/supercharging 1884
1 Turbocharger 1884
1 1 Assembly overview – turbocharger 1884
1 1 1 Assembly overview – turbocharger 1884
1 1 2 Assembly overview – turbocharger, water-cooled turbocharger 1886
1 1 3 Assembly overview – turbocharger, vehicles with particulate filter or catalytic converter 1889
1 2 Removing and installing turbocharger 1892
1 2 1 Removing and installing turbocharger 1892
1 2 2 Removing and installing turbocharger, water-cooled turbocharger 1898
1 2 3 Removing and installing turbocharger, vehicles with particulate filter or catalytic converter 1905
1 3 Renewing vacuum unit for turbocharger 1909
1 3 1 Renewing vacuum unit for turbocharger, versions 1 and 2 1909
1 3 2 Renewing vacuum unit for turbocharger, version 3 1916
1 4 Removing and installing connection for turbocharger 1922
2 Charge air system 1925
2 1 Assembly overview – charge air system 1925
2 2 Removing and installing charge pressure sender -G31- 1928
2 3 Checking charge air system for leaks 1928
2 4 Checking charge air cooler for leaks 1931
2 5 Removing and installing air intake pipe 1936
2 5 1 Removing and installing air pipe, vehicles with non-water-cooled turbocharger 1936
2 5 2 Removing and installing air pipe, vehicles with water-cooled turbocharger 1937
23 – Mixture preparation – injection 1939
1 Injection system 1939
1 1 Schematic overview – fuel system 1939
1 2 Overview of fitting locations – injection system 1941
1 2 1 Overview of fitting locations – engine compartment 1941
1 2 2 Overview of fitting locations – engine compartment, vehicles with SCR system 1945
1 2 3 Overview of fitting locations on engine (from above) 1947
1 2 4 Overview of fitting locations – front view of engine 1949
1 2 5 Overview of fitting locations – rear view of engine, vehicles without SCR system 1950
1 2 6 Overview of fitting locations – rear view of engine, vehicles with SCR system 1951
1 3 Filling/bleeding fuel system 1953
1 4 Checking fuel system for leaks 1954
2 Vacuum system 1955
2 1 Connection diagram – vacuum system 1955
2 2 Checking vacuum system 1956
3 Injectors/high-pressure accumulator (rail) 1957
3 1 Assembly overview – injectors 1957
3 2 Assembly overview – fuel rail 1959
3 3 Adapting correction values for injectors 1960
3 4 Testing injectors 1961
3 5 Checking return flow rate of injectors with engine running 1962
3 6 Checking return flow rate of injectors at starter speed 1964
3 7 Checking open injectors 1966
3 8 Removing and installing injectors 1967
3 9 Removing and installing high-pressure lines 1971
3 9 1 Removing high-pressure pipe between fuel rail and high-pressure pump 1971
3 9 2 Installing high-pressure line 1972
3 10 Removing and installing fuel rail 1974
4 Air filter 1976
4 1 Assembly overview – air filter housing 1976
4 2 Removing and installing air filter housing 1979
5 Intake manifold 1981
5 1 Assembly overview – intake manifold 1981
5 2 Removing and installing intake manifold 1985
5 3 Removing and installing throttle valve module -J338- 1990
6 Senders and sensors 1994
6 1 Removing and installing fuel pressure regulating valve -N276- 1994
6 1 1 Versions of fuel pressure regulating valve -N276- 1994
6 1 2 Removing and installing fuel pressure regulating valve, version 1 1995
6 1 3 Removing and installing fuel pressure regulating valve -N276-, version 2 1996
6 2 Checking fuel pressure regulating valve -N276- 1999
6 3 Removing and installing fuel pressure sender -G247- 2000
6 4 Removing and installing air mass meter -G70- 2002
6 5 Removing and installing pressure differential sender -G505- 2004
6 5 1 Removing and installing pressure differential sender -G505-, version 1 2004
6 5 2 Removing and installing pressure differential sender -G505-, version 2 2006
6 6 Removing and installing exhaust gas pressure sensor 1 -G450- 2007
6 7 Removing and installing NOx sender 2 -G687- 2008
6 8 Removing and installing charge air temperature sender ahead of charge air cooler -G810- 2010
6 9 Removing and installing charge air temperature sender after charge air cooler -G811- 2011
6 10 Removing and installing fuel temperature sender -G81- 2011
6 11 Removing and installing control unit for NOx sender -GX30- 2013
6 11 1 Versions of NOx sender control unit -GX30- 2013
6 11 2 Removing and installing control unit for NOx sender -GX30-, version A 2014
6 11 3 Removing and installing control unit for NOx sender -GX30-, version B 2018
6 12 Removing and installing temperature and pressure sender for low-pressure fuel system -GX20- 2021
7 Engine/motor control unit 2023
7 1 Removing and installing engine control unit -J623- 2023
7 1 1 Removing and installing engine control unit -J623- 2023
7 1 2 Removing and installing engine control unit -J623- (with metal locking plate) 2024
7 1 3 Removing and installing engine control unit -J623- (with protective housing) 2027
8 High-pressure pump 2030
8 1 Assembly overview – high-pressure pump 2030
8 2 Removing and installing high-pressure pump 2031
9 Lambda probe 2035
9 1 Assembly overview – Lambda probe 2035
9 1 1 Assembly overview – Lambda probe; vehicles without SCR system 2035
9 1 2 Assembly overview – Lambda probe; vehicles with SCR system 2036
9 2 Removing and installing lambda probe 2038
9 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 2038
9 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 2039
26 – Exhaust system 2042
1 Exhaust pipes and silencers 2042
1 1 Assembly overview – silencers 2042
1 1 1 Assembly overview – silencers, vehicles with 1 6 l and 2 0 l engine 2042
1 1 2 Assembly overview – silencers, vehicles with 2 0 l engine with 140 kW and SCR system 2044
1 1 3 Assembly overview – silencer, vehicles with four-wheel drive 2046
1 2 Assembly overview – front exhaust pipe 2048
1 3 Removing and installing front exhaust pipe 2050
1 4 Separating exhaust pipes from silencers 2051
1 5 Removing and installing rear silencer 2053
1 5 1 Removing and installing rear silencer, vehicles with front-wheel drive 2053
1 5 2 Removing and installing rear silencer, vehicles with all-wheel drive 2054
1 6 Aligning exhaust system free of stress 2055
1 7 Checking exhaust system for leaks 2056
1 8 Installation position of clamp 2056
2 Emission control 2059
2 1 Assembly overview – emission control 2059
2 1 1 Versions of emission control system 2059
2 1 2 Assembly overview – emission control, vehicles emission control module 2059
2 1 3 Assembly overview – emission control, vehicles with particulate filter or catalytic converter 2062
2 2 Removing and installing catalytic converter 2064
2 3 Removing and installing particulate filter 2066
2 4 Removing and installing emission control module 2066
2 5 Removing and installing exhaust flap control unit -J883- 2078
3 SCR system (selective catalytic reduction) 2080
3 1 Assembly overview – reducing agent tank 2080
3 2 Assembly overview – reducing agent supply line 2082
3 3 Assembly overview – delivery module for reducing agent 2083
3 4 Removing and installing reducing agent tank 2083
3 5 Removing and installing front section of reducing agent supply line 2086
3 6 Removing and installing delivery module for reducing agent 2095
3 7 Removing and installing injector for reduction agent -N474- 2098
3 8 Removing and installing control unit for reducing-agent heater -J891- 2101
3 8 1 Removing and installing control unit for reducing agent heater -J891-, Passat Variant 2101
3 8 2 Removing and installing control unit for reducing agent heater -J891-, Passat saloon 2102
3 8 3 Removing and installing control unit for reducing agent heater -J891-, Arteon 2103
3 9 Assembly overview – injector for reducing agent 2104
3 10 Draining reducing agent tank 2106
3 11 Removing and installing rear section of reducing agent supply line 2109
3 12 Removing and installing filler pipe for reducing agent tank 2110
3 13 Disconnecting reducing agent supply line 2112
3 14 SCR – resetting learnt values 2115
4 Exhaust gas temperature regulation 2117
4 1 Assembly overview – exhaust gas temperature regulation 2117
4 1 1 Assembly overview – exhaust gas temperature regulation 2117
4 1 2 Assembly overview – exhaust gas temperature regulation, vehicles with SCR system 2119
4 1 3 Assembly overview – exhaust gas temperature regulation, vehicles with particulate filter or catalytic converter 2121
4 2 Removing and installing exhaust gas temperature sender 1 -G235- 2121
4 2 1 Removing and installing exhaust gas temperature sender 1 -G235- 2121
4 2 2 Removing and installing exhaust gas temperature sender 1 -G235-, vehicles with SCR 2123
4 2 3 Removing and installing exhaust gas temperature sender 1 -G235-, vehicles with water-cooled turbocharger 2125
4 3 Removing and installing exhaust gas temperature sender 2 -G448- 2127
4 3 1 Removing and installing exhaust gas temperature sender 2 -G448-, vehicles with 1 6 l diesel engine 2127
4 3 2 Removing and installing exhaust gas temperature sender 2 -G448-, vehicles with 2 0 l engine and SCR system 2130
4 3 3 Removing and installing exhaust gas temperature sender 2 -G448-, vehicles with 2 0 l engine 2132
4 4 Removing and installing exhaust gas temperature sender 3 -G495- 2135
4 4 1 Removing and installing exhaust gas temperature sender 3 -G495- 2135
4 4 2 Removing and installing exhaust gas temperature sender 3 -G495-, vehicles with SCR 2136
4 5 Removing and installing exhaust gas temperature sender 4 -G648- 2138
5 Exhaust gas recirculation 2141
5 1 Assembly overview – exhaust gas recirculation 2141
5 1 1 Assembly overview – exhaust gas recirculation 2141
5 1 2 Assembly overview – exhaust gas recirculation, vehicles with particulate filter or catalytic converter 2143
5 2 Assembly overview – exhaust gas recirculation valve 1 -GX5- 2145
5 3 Removing and installing exhaust gas recirculation cooler 2146
5 3 1 Removing and installing exhaust gas recirculation cooler 2146
5 3 2 Removing and installing exhaust gas recirculation cooler, vehicles with particulate filter or catalytic converter 2151
5 4 Removing and installing exhaust gas recirculation valve 1 -GX5- 2153
5 5 Removing and installing exhaust gas recirculation valve 2 -GX6- 2155
5 6 Removing and installing exhaust gas recirculation temperature sensor -G98- 2156
5 6 1 Removing and installing exhaust gas recirculation temperature sensor -G98-, vehicles with particulate filter or catalytic converter 2156
5 6 2 Removing and installing exhaust gas recirculation temperature sensor -G98-, vehicles with emission control module and selective catalytic reduction system 2158
5 7 Checking exhaust gas recirculation cooler for leaks 2159
28 – Glow plug system 2160
1 Glow plug system 2160
1 1 Assembly overview – glow plug system 2160
1 2 Removing and installing glow plug 2162
1 3 Removing and installing automatic glow period control unit -J179- 2165
1 4 Removing and installing Hall sender -G40- 2165
1 5 Removing and installing engine speed sender -G28- 2166
D4B804A2FDC 4 cylinder common rail engine (2 0 l 4V bi turbo EA 288) 2168
00 – Technical data 2176
1 Safety information 2176
1 1 Safety regulations for working on fuel supply 2176
1 2 Safety measures when working on vehicles with start/stop system 2177
1 3 Safety precautions when using testers and measuring instruments during a road test 2177
1 4 Safety precautions when working on the cooling system 2177
1 5 Safety precautions when working on SCR system 2177
1 6 Safety precautions when working on exhaust system 2178
2 Identification 2180
2 1 Engine number/engine data 2180
3 Repair instructions 2182
3 1 Rules for cleanliness 2182
3 2 Foreign objects in engine 2182
3 3 Contact corrosion 2182
3 4 Routing and attachment of lines 2183
3 5 Fitting radiator and condensers 2183
10 – Removing and installing engine 2184
1 Removing and installing engine 2184
1 1 Removing engine 2184
1 2 Separating engine and gearbox 2196
1 3 Securing engine on engine and gearbox support 2199
1 4 Installing engine 2200
2 Assembly mountings 2205
2 1 Assembly overview – assembly mountings 2205
2 1 1 Assembly overview – assembly mountings, Passat and Arteon 2205
2 1 2 Assembly overview – assembly mountings, Tiguan 2207
2 2 Removing and installing engine mounting 2209
2 3 Removing and installing gearbox mounting 2211
2 3 1 Removing and installing gearbox mounting, Passat and Arteon 2211
2 3 2 Removing and installing gearbox mountings, Tiguan 2213
2 4 Removing and installing pendulum support 2215
2 5 Supporting engine in installation position 2216
2 5 1 Supporting engine in installation position, Passat 2216
2 5 2 Supporting engine in installation position, Tiguan 2221
2 5 3 Supporting engine in installation position, Arteon 2227
2 6 Adjusting assembly mountings 2233
2 6 1 Adjusting assembly mountings, Passat and Arteon 2233
2 6 2 Adjusting assembly mountings, Tiguan 2234
2 7 Checking adjustment of assembly mountings 2236
3 Engine cover panel 2237
3 1 Removing and installing engine cover 2237
13 – Crankshaft group 2238
1 Cylinder block (pulley end) 2238
1 1 Assembly overview – cylinder block (pulley end) 2238
1 2 Assembly overview – sealing flange, belt pulley end 2241
1 3 Removing and installing poly-V belt 2243
1 4 Removing and installing tensioner for poly V-belt 2244
1 5 Removing and installing vibration damper 2245
1 6 Removing and installing bracket for ancillaries 2246
1 7 Removing and installing engine support 2248
1 8 Removing and installing sealing flange on pulley end 2250
1 9 Renewing caps in cylinder block (pulley end) 2253
2 Cylinder block, gearbox end 2256
2 1 Assembly overview – cylinder block, gearbox end 2256
2 2 Removing and installing flywheel 2259
2 3 Removing and installing sealing flange on gearbox side 2261
2 4 Renewing caps in cylinder block (gearbox end) 2271
3 Crankshaft 2273
3 1 Assembly overview – crankshaft 2273
3 2 Crankshaft dimensions 2273
3 3 Renewing needle bearing in crankshaft 2273
3 4 Measuring axial clearance of crankshaft 2276
4 Pistons and conrods 2278
4 1 Assembly overview – pistons and conrods 2278
4 2 Removing and installing pistons 2281
4 3 Measuring piston projection at TDC 2283
4 4 Checking pistons and cylinder bores 2285
4 5 Separating new conrod 2287
4 6 Checking radial clearance of conrods 2288
15 – Cylinder head, valve gear 2289
1 Cylinder head 2289
1 1 Assembly overview – cylinder head 2289
1 2 Assembly overview – cylinder head cover 2293
1 2 1 Assembly overview – cylinder head cover 2293
1 2 2 Assembly overview – cylinder head cover with add-on parts 2295
1 3 Removing and installing cylinder head 2296
1 4 Removing and installing cylinder head cover 2303
1 5 Removing and installing injector seals 2306
1 6 Removing and installing camshaft housing 2308
1 7 Checking compression 2312
2 Toothed belt drive 2315
2 1 Assembly overview – toothed belt cover 2315
2 2 Assembly overview – toothed belt 2315
2 3 Removing and installing toothed belt guard 2317
2 3 1 Removing and installing upper toothed belt guard 2317
2 3 2 Removing and installing lower toothed belt guard 2321
2 4 Removing and installing toothed belt 2323
2 5 Removing toothed belt from camshaft 2338
3 Valve gear 2344
3 1 Assembly overview – valve gear 2344
3 2 Measuring axial play of camshaft 2347
3 3 Removing and installing camshaft oil seal 2347
3 4 Checking hydraulic compensation elements 2350
3 5 Removing and installing valve stem seals 2351
3 5 1 Removing and installing valve stem seals (cylinder head installed) 2351
3 5 2 Removing and installing valve stem seals (cylinder head removed) 2354
4 Inlet and exhaust valves 2359
4 1 Checking valve guides 2359
4 2 Checking valves 2360
4 3 Valve dimensions 2360
17 – Lubrication 2361
1 Sump, oil pump 2361
1 1 Assembly overview – sump/oil pump 2361
1 2 Engine oil: 2363
1 3 Removing and installing oil sump 2363
1 4 Removing and installing oil pump 2368
1 5 Removing and installing oil level and oil temperature sender -G266- 2369
2 Engine oil cooler 2371
3 Oil filter, oil pressure switch 2372
3 1 Assembly overview – oil filter housing, oil pressure switch 2372
3 2 Removing and installing oil pressure switch -F1- 2374
3 3 Removing and installing oil pressure switch for reduced oil pressure -F378- 2376
3 4 Checking oil pressure 2378
3 5 Removing and installing oil filter housing 2378
3 6 Removing and installing oil pressure regulating valve -N428- 2381
19 – Cooling 2384
1 Cooling system/coolant 2384
1 1 Connection diagram – coolant hoses 2384
1 2 Checking cooling system for leaks 2386
1 3 Draining coolant 2390
1 4 Filling with coolant 2392
1 4 1 Filling with coolant without electric vacuum pump 2392
1 4 2 Filling coolant with electric vacuum pump -VAS 6096/2- 2400
1 4 3 Checking electric vacuum pump -VAS 6096/2- 2411
1 5 Checking filling quality of cooling system 2412
1 6 Flushing cooling system 2414
1 6 1 Flushing cooling system, quick reference guide 2437
2 Coolant pump, regulation of cooling system 2439
2 1 Assembly overview – coolant pump, thermostat 2439
2 1 1 Assembly overview – coolant pump/thermostat, version 1 2439
2 1 2 Assembly overview – coolant pump/thermostat, version 2 2441
2 2 Assembly overview – electric coolant pump 2443
2 3 Assembly overview – coolant temperature sender 2445
2 3 1 Assembly overview – coolant temperature sender -G62- 2445
2 3 2 Assembly overview – coolant temperature sender 2 -G802- 2445
2 4 Assembly overview – actuator for engine temperature regulation -N493- 2446
2 4 1 Assembly overview – actuator for engine temperature regulation -N493-, Passat and Arteon 2446
2 4 2 Assembly overview – actuator for engine temperature regulation -N493-, Tiguan 2447
2 5 Removing and installing electric coolant pump 2448
2 5 1 Removing and installing charge air cooling pump -V188- 2448
2 5 2 Removing and installing auxiliary pump for heating -V488- 2451
2 6 Removing and installing coolant pump 2454
2 7 Removing and installing thermostat 2455
2 7 1 Removing and installing thermostat, version 1 2455
2 7 2 Removing and installing thermostat, version 2 2456
2 8 Checking thermostat 2459
2 9 Removing and installing coolant valve for cylinder head -N489- 2460
2 10 Removing and installing coolant temperature sender -G62- 2460
2 11 Removing and installing coolant temperature sender 2 -G802- 2462
2 12 Removing and installing actuator for engine temperature regulation -N493- 2464
2 12 1 Removing and installing actuator for engine temperature regulation -N493-, Passat and Arteon 2464
2 12 2 Removing and installing actuator for engine temperature regulation -N493-, Tiguan 2467
3 Coolant pipes 2471
3 1 Assembly overview – coolant pipes 2471
3 2 Removing and installing coolant pipes 2475
3 2 1 Removing and installing upper front coolant pipe 2475
3 2 2 Removing and installing front coolant pipes 2476
3 2 3 Removing and installing front coolant connection 2478
3 2 4 Removing and installing coolant pipe at front below intake manifold 2479
3 2 5 Removing and installing front right coolant pipe 2480
3 2 6 Removing and installing lower front coolant pipe 2482
3 2 7 Removing and installing left coolant pipes 2485
3 2 8 Removing and installing rear coolant pipe 2487
3 2 9 Removing and installing rear right coolant pipe 2490
3 2 10 Upper left coolant pipe on cylinder head cover 2492
3 2 11 Removing and installing upper left coolant pipes 2494
3 2 12 Removing and installing coolant pipes on turbocharger 2497
4 Radiator, radiator fan 2500
4 1 Assembly overview – radiator/radiator fan 2500
4 2 Assembly overview – auxiliary radiator 2502
4 3 Assembly overview – radiator cowl and radiator fan 2503
4 4 Removing and installing radiator 2504
4 5 Removing and installing water radiator for charge air cooling circuit 2507
4 6 Removing and installing radiator cowl 2510
4 6 1 Removing and installing radiator cowl, Passat 2510
4 6 2 Removing and installing radiator cowl, Tiguan and Arteon 2512
4 7 Removing and installing radiator fan 2513
4 7 1 Removing and installing radiator fan -V7- 2513
4 7 2 Removing and installing radiator fan -V177- 2514
4 8 Removing and installing auxiliary radiator 2514
21 – Turbocharging/supercharging 2518
1 Turbocharger 2518
1 1 Assembly overview – turbocharger 2518
1 1 1 Assembly overview – turbocharger 2518
1 1 2 Assembly overview – heat shields on turbocharger 2520
1 1 3 Assembly overview – coolant lines on turbocharger 2521
1 1 4 Assembly overview – high-pressure turbocharger 2522
1 1 5 Assembly overview – low-pressure turbocharger 2524
1 1 6 Assembly overview – turbocharger/exhaust manifold 2526
1 1 7 Assembly overview – senders and sensors on turbocharger 2528
1 1 8 Assembly overview – oil lines on turbochargers 2529
1 2 Removing and installing turbocharger 2531
1 2 1 Removing and installing high-pressure turbocharger 2531
1 2 2 Removing and installing low-pressure turbocharger 2536
1 3 Removing and installing vacuum unit for turbocharger 2543
1 3 1 Removing and installing vacuum unit with regulating flap potentiometer -G584- on low-pressure turbocharger 2543
1 3 2 Removing and installing vacuum unit for wastegate on low-pressure turbocharger 2546
1 4 Removing and installing turbocharger 1 control unit -J724- 2549
2 Charge air system 2554
2 1 Assembly overview – charge air system 2554
2 2 Removing and installing charge pressure sender -G31- 2556
2 3 Removing and installing charge pressure sender 2 -G447- 2556
2 4 Checking charge air system for leaks 2557
2 5 Removing and installing air pipe 2559
2 6 Checking charge air cooler for leaks 2566
23 – Mixture preparation – injection 2572
1 Injection system 2572
1 1 Schematic overview – fuel system 2572
1 2 Overview of fitting locations – injection system 2573
1 2 1 Overview of fitting locations – injection system, engine compartment 2573
1 2 2 Overview of fitting locations – injection system, engine from above 2577
1 2 3 Overview of fitting locations – injection system, front view of engine 2579
1 2 4 Overview of fitting locations – injection system, rear view of engine 2582
1 2 5 Overview of fitting locations – injection system, engine from left 2584
1 2 6 Overview of fitting locations – electrical connectors, Passat and Arteon 2585
1 2 7 Overview of fitting locations – electrical connectors, Tiguan 2586
1 3 Filling/bleeding fuel system 2587
1 4 Checking fuel system for leaks 2587
2 Vacuum system 2589
2 1 Connection diagram – vacuum system 2589
2 1 1 Connection diagram – vacuum system 2589
2 1 2 Overview of fitting locations – vacuum system 2591
2 2 Checking vacuum system 2592
3 Injectors/high-pressure accumulator (rail) 2594
3 1 Assembly overview – injectors 2594
3 2 Assembly overview – fuel rail 2596
3 3 Adapting correction values for injectors 2598
3 4 Testing injectors 2599
3 5 Checking return flow rate of injectors with engine running 2599
3 6 Checking return flow rate of injectors at starter speed 2602
3 7 Removing and installing injectors 2604
3 8 Removing and installing high-pressure lines 2608
3 8 1 Removing high-pressure pipe between fuel rail and high-pressure pump 2608
3 8 2 Removing and installing high-pressure line between fuel rail and injectors 2609
3 9 Removing and installing fuel rail 2614
4 Air filter 2618
4 1 Assembly overview – air filter housing 2618
4 2 Removing and installing air filter housing 2620
5 Intake manifold 2624
5 1 Assembly overview – intake manifold 2624
5 2 Removing and installing intake manifold 2627
5 3 Removing and installing throttle valve module -J338- 2633
6 Senders and sensors 2636
6 1 Removing and installing fuel pressure regulating valve -N276- 2636
6 2 Checking fuel pressure regulating valve -N276- 2638
6 3 Removing and installing fuel pressure sender -G247- 2640
6 4 Removing and installing air mass meter -G70- 2641
6 5 Removing and installing pressure differential sender -G505- 2643
6 6 Removing and installing exhaust gas pressure sensor 1 -G450- 2644
6 7 Removing and installing charge air temperature sender ahead of charge air cooler -G810- 2646
6 8 Removing and installing charge air temperature sender after charge air cooler -G811- 2646
6 9 Removing and installing fuel temperature sender -G81- 2647
6 10 Removing and installing control unit for NOx sender -GX30- 2648
6 10 1 Removing and installing control unit for NOx sender -GX30-, Passat and Arteon 2648
6 10 2 Removing and installing control unit for NOx sender -GX30-, Tiguan 2650
6 11 Assembly overview – NOx sender control unit -GX30- 2652
6 12 Removing and installing control unit 2 for NOx sender -GX46- 2653
6 13 Removing and installing particle sensor -G784- 2655
7 Engine control unit 2657
7 1 Removing and installing engine control unit -J623- 2657
7 1 1 Removing and installing engine control unit -J623- 2657
7 1 2 Removing and installing engine control unit -J623- (with metal locking plate) 2658
7 1 3 Removing and installing engine control unit -J623- (with protective housing) 2661
8 High-pressure pump 2665
8 1 Assembly overview – high-pressure pump 2665
8 2 Removing and installing high-pressure pump 2667
9 Lambda probe 2671
9 1 Assembly overview – Lambda probe 2671
9 2 Removing and installing Lambda probe 2671
9 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 2671
26 – Exhaust system 2674
1 Exhaust pipes and silencers 2674
1 1 Assembly overview – silencers 2674
1 1 1 Assembly overview – silencers, Passat and Arteon 2674
1 1 2 Assembly overview – silencers, Tiguan 2676
1 2 Removing and installing front exhaust pipe 2678
1 2 1 Removing and installing front exhaust pipe, Passat and Arteon 2678
1 2 2 Removing and installing front exhaust pipe, Tiguan 2679
1 3 Removing and installing rear silencer 2681
1 3 1 Removing and installing rear silencer, Passat and Arteon 2681
1 3 2 Removing and installing rear silencer, Tiguan 2683
1 4 Aligning exhaust system free of stress 2685
1 5 Checking exhaust system for leaks 2685
1 6 Installation position of clamp 2686
1 7 Assembly overview – front exhaust pipe 2686
1 7 1 Assembly overview – front exhaust pipe, Passat and Arteon 2686
1 7 2 Assembly overview – front exhaust pipe, Tiguan 2687
1 7 3 Assembly overview – front exhaust pipe, vehicles with control unit 2 for NOx sender -GX46- and particulate sensor -G784- 2690
2 Emission control 2693
2 1 Assembly overview – emission control 2693
2 2 Removing and installing emission control module 2700
2 3 Removing and installing exhaust flap control unit -J883- 2704
3 SCR system (selective catalytic reduction) 2707
3 1 Assembly overview – reducing agent tank 2707
3 1 1 Assembly overview – reducing agent tank, Passat and Arteon 2707
3 1 2 Assembly overview – tank for reducing agent, Tiguan 2709
3 2 Assembly overview – reducing agent supply line 2711
3 3 Assembly overview – delivery module for reducing agent 2712
3 4 Removing and installing reducing agent tank 2713
3 4 1 Removing and installing reducing agent tank, Passat and Arteon 2713
3 4 2 Removing and installing tank for reducing agent, Tiguan 2716
3 5 Removing and installing front section of reducing agent supply line 2719
3 5 1 Removing and installing front section of reducing agent supply line, Passat and Arteon 2719
3 5 2 Removing and installing front section of reducing agent supply line, Tiguan 2726
3 6 Removing and installing delivery module for reducing agent 2734
3 7 Removing and installing injector for reduction agent -N474- 2736
3 8 Removing and installing control unit for reducing-agent heater -J891- 2739
3 8 1 Removing and installing control unit for reducing agent heater -J891-, Passat Variant 2739
3 8 2 Removing and installing control unit for reducing agent heater -J891-, Passat saloon 2740
3 8 3 Removing and installing control unit for reducing-agent heater -J891-, Tiguan 2741
3 8 4 Removing and installing control unit for reducing agent heater -J891-, Arteon 2742
3 9 Assembly overview – injector for reducing agent 2743
3 10 Draining reducing agent tank 2744
3 10 1 Draining reducing agent tank, Passat and Arteon 2744
3 10 2 Emptying tank for reducing agent, Tiguan 2748
3 11 Removing and installing rear section of reducing agent supply line 2751
3 12 Removing and installing filler pipe for reducing agent tank 2753
3 12 1 Removing and installing filler pipe for reducing agent tank, Passat and Arteon 2753
3 12 2 Removing and installing filler tube for reducing agent tank, Tiguan 2754
3 13 Disconnecting reducing agent supply line 2757
3 14 SCR – resetting learnt values 2760
4 Exhaust gas temperature regulation 2761
4 1 Assembly overview – exhaust gas temperature regulation 2761
4 2 Removing and installing exhaust gas temperature sender 1 -G235- 2763
4 3 Removing and installing exhaust gas temperature sender 2 -G448- 2769
4 4 Removing and installing exhaust gas temperature sender 3 -G495- 2771
4 5 Removing and installing exhaust gas temperature sender 4 -G648- 2772
5 Exhaust gas recirculation 2775
5 1 Assembly overview – exhaust gas recirculation 2775
5 1 1 Assembly overview – exhaust gas recirculation, exhaust gas recirculation valve 2 -GX6- 2775
5 1 2 Assembly overview – exhaust gas recirculation, exhaust gas recirculation valve 1 -GX5- 2777
5 2 Removing and installing exhaust gas recirculation cooler 2778
5 3 Removing and installing exhaust gas recirculation valve 1 -GX5- 2784
5 4 Removing and installing exhaust gas recirculation valve 2 -GX6- 2786
5 5 Checking exhaust gas recirculation cooler for leaks 2789
6 Exhaust manifold 2790
6 1 Assembly overview – exhaust manifold 2790
6 2 Removing and installing exhaust manifold 2791
28 – Glow plug system 2793
1 Glow plug system 2793
1 1 Assembly overview – glow plug system 2793
1 2 Removing and installing glow plug 2794
1 3 Removing and installing automatic glow period control unit -J179- 2798
1 4 Removing and installing Hall sender -G40- 2798
1 5 Removing and installing engine speed sender -G28- 2799
D4B804A2FDD Running gear axles steering 2801
00 – Technical data 2807
1 Safety information 2807
1 1 Safety measures when working on vehicles with a start/stop system 2807
1 2 Safety precautions when working on high-voltage system 2807
1 3 Safety precautions when working in the vicinity of high-voltage components 2808
1 4 Safety precautions when working on subframe 2808
2 Repair instructions 2809
2 1 Leaks at shock absorbers 2809
2 2 Noises from shock absorbers 2809
2 3 Checking shock absorbers when removed 2810
2 4 Steering rack 2810
2 5 Gaskets and seals 2811
2 6 Nuts and bolts 2811
2 7 Electrical components 2811
2 8 Raising suspension to unladen position (vehicles with coil springs) 2812
3 Evaluating accident vehicles 2816
3 1 Check list for evaluating running gear on accident vehicles 2816
4 Disposal 2818
4 1 Releasing gas and draining front gas-filled shock absorbers 2818
4 1 1 Releasing gas and draining front gas-filled shock absorbers, conventional shock absorbers 2818
4 1 2 Releasing gas and draining front gas-filled shock absorbers, DCC shock absorbers 2819
4 2 Releasing gas and draining rear gas-filled shock absorbers 2820
4 2 1 Releasing gas and draining rear gas-filled shock absorbers, conventional shock absorbers 2820
4 2 2 Releasing gas and draining rear gas-filled shock absorbers, DCC shock absorbers 2820
40 – Front suspension 2822
1 Front axle 2822
1 1 Overview of fitting locations – front axle 2822
2 Subframe 2825
2 1 Assembly overview – subframe 2825
2 2 Removing and installing subframe without steering rack 2825
2 3 Removing and installing subframe with steering rack 2831
2 4 Repairing subframe 2839
2 5 Repairing thread in longitudinal member 2852
2 6 Fixing subframe in position 2852
2 7 Lowering subframe 2856
3 Anti-roll bar 2862
3 1 Assembly overview – anti-roll bar 2862
3 2 Removing and installing anti-roll bar 2862
3 3 Removing and installing coupling rod 2868
4 Suspension strut, upper suspension link 2870
4 1 Assembly overview – suspension strut, upper suspension link 2870
4 2 Removing and installing suspension strut 2871
4 3 Repairing suspension strut 2882
5 Lower suspension link, swivel joint 2887
5 1 Assembly overview – lower suspension link, swivel joint 2887
5 2 Removing and installing lower suspension link 2888
5 2 1 Removing and installing lower suspension link, vehicle with manual gearbox or dual clutch gearbox 0CW 2888
5 2 2 Removing and installing lower suspension link, vehicle with dual clutch gearbox 0D9, 0DD, except Passat GTE 2891
5 2 3 Removing and installing lower suspension link, vehicle with dual clutch gearbox 0DL, 0GC and Passat GTE 2896
5 3 Checking swivel joint 2902
5 4 Removing and installing swivel joint 2902
5 5 Renewing front bonded rubber bush for lower suspension link 2907
5 6 Renewing rear bonded rubber bush for lower suspension link 2911
6 Wheel bearing 2915
6 1 Assembly overview – wheel bearing assembly 2915
6 2 Removing and installing wheel bearing housing 2915
6 3 Removing and installing wheel bearing unit 2922
7 Drive shaft 2927
7 1 Overview – drive shaft 2927
7 2 Assembly overview – drive shaft 2928
7 2 1 Assembly overview – drive shaft, constant velocity joint VL100 2928
7 2 2 Assembly overview – drive shaft, constant velocity joint VL107 2930
7 2 3 Assembly overview – drive shaft, triple roller joint AAR3300i 2932
7 3 Removing and installing drive shaft 2934
7 3 1 Removing and installing drive shaft, constant velocity joints VL100 and VL107 2934
7 3 2 Removing and installing drive shaft, triple roller joint AAR3300i pushed into gearbox 2940
7 3 3 Removing and installing drive shaft, triple roller joint AAR3300i pushed onto flange shaft 2946
7 3 4 Removing and installing drive shafts, triple roller joint AAR3300i bolted 2951
7 4 Loosening and tightening threaded connections of drive shaft 2956
7 5 Removing and installing drive shaft heat shield 2957
7 6 Dismantling and assembling drive shaft 2958
7 6 1 Dismantling and assembling drive shaft, constant velocity joint VL100 2958
7 6 2 Dismantling and assembling drive shaft, constant velocity joint VL107 2963
7 6 3 Dismantling and assembling drive shaft, triple roller joint AAR3300i pushed into gearbox, bolted on 2969
7 6 4 Dismantling and assembling drive shaft, triple roller joint AAR3300i pushed onto flange shaft 2975
7 7 Checking outer constant velocity joint 2982
7 8 Checking inner constant velocity joint 2983
42 – Rear suspension 2987
1 Rear axle 2987
1 1 Overview – rear axle 2987
1 2 Lowering rear axle 2989
1 2 1 Lowering rear axle, front-wheel drive except Passat GTE 2989
1 2 2 Lowering rear axle, front-wheel drive only Passat GTE 2992
1 2 3 Lowering rear axle, four-wheel drive 2996
1 3 Removing and installing rear axle 2999
1 3 1 Removing and installing rear axle, front-wheel drive, except Passat GTE 2999
1 3 2 Removing and installing rear axle, front-wheel drive, only Passat GTE 3003
1 3 3 Removing and installing rear axle, all-wheel drive 3008
1 4 Removing and installing shield for rear axle 3013
2 Subframe 3015
2 1 Assembly overview – subframe 3015
2 1 1 Assembly overview – subframe, multi-link suspension, front-wheel drive 3015
2 1 2 Assembly overview – subframe, multi-link suspension, four-wheel drive 3015
2 2 Assembly overview – add-on parts for subframe 3016
2 3 Fixing subframe in position 3017
2 3 1 Fixing position of subframe, front-wheel drive except Passat GTE 3017
2 3 2 Fixing position of subframe, front-wheel drive, only Passat GTE 3022
2 3 3 Fixing position of subframe, four-wheel drive 3027
2 4 Repairing subframe 3032
2 4 1 Renewing bonded rubber bush 3032
2 4 2 Renewing rear bonded rubber bush 3039
3 Anti-roll bar 3047
3 1 Assembly overview – anti-roll bar 3047
3 1 1 Assembly overview – anti-roll bar, multi-link suspension, front-wheel drive 3047
3 1 2 Assembly overview – anti-roll bar, multi-link suspension, four-wheel drive 3047
3 2 Removing and installing anti-roll bar 3048
3 3 Removing and installing coupling rod 3050
4 Suspension link, track rod 3053
4 1 Assembly overview – transverse link 3053
4 1 1 Assembly overview – transverse link, multi-link suspension, front-wheel drive 3053
4 1 2 Assembly overview – transverse link, multi-link suspension, four-wheel drive 3055
4 2 Assembly overview – track rod 3057
4 2 1 Assembly overview – track rod, multi-link suspension, front-wheel drive 3057
4 2 2 Assembly overview – track rod, multi-link suspension, four-wheel drive 3057
4 3 Removing and installing upper transverse link 3058
4 4 Removing and installing lower transverse link 3059
4 5 Removing and installing track rod 3061
5 Suspension strut, shock absorber, spring 3064
5 1 Assembly overview – suspension strut, shock absorber, spring 3064
5 2 Removing and installing shock absorber 3065
5 3 Repairing shock absorber 3069
5 4 Removing and installing spring 3071
6 Wheel bearing assembly, trailing arm 3079
6 1 Assembly overview – wheel bearing assembly 3079
6 1 1 Assembly overview – suspension, multi-link suspension, front-wheel drive 3079
6 1 2 Assembly overview – suspension, multi-link suspension, four-wheel drive 3080
6 2 Assembly overview – trailing arm 3081
6 3 Removing and installing wheel bearing housing 3082
6 3 1 Removing and installing wheel bearing housing, multi-link suspension, front-wheel drive 3082
6 3 2 Removing and installing wheel bearing housing, multi-link suspension, four-wheel drive 3088
6 4 Removing and installing wheel bearing unit 3094
6 4 1 Removing and installing wheel bearing unit, multi-link suspension, front-wheel drive 3094
6 4 2 Removing and installing wheel bearing unit, multi-link suspension, four-wheel drive 3099
6 5 Renewing bonded rubber bush for wheel bearing housing 3102
6 6 Removing and installing trailing arm with mounting bracket 3105
6 7 Repairing trailing arm 3109
6 7 1 Repairing trailing arm, hydro-bush 3109
6 7 2 Repairing trailing arm, conventional bearing 3114
7 Drive shaft 3120
7 1 Assembly overview – drive shaft 3120
7 1 1 Assembly overview – drive shaft, constant velocity joint VL90 3120
7 1 2 Assembly overview – drive shaft, constant velocity joint VL100i 3122
7 2 Loosening and tightening threaded connections of drive shaft 3124
7 3 Removing and installing drive shaft 3125
7 4 Dismantling and assembling drive shaft 3133
7 5 Checking outer constant velocity joint 3138
7 6 Checking inner constant velocity joint 3140
43 – Self-levelling suspension 3143
1 Electronic damping control 3143
1 1 Overview of fitting locations – electronically controlled damping system 3143
1 2 Removing and installing electronically controlled damping control unit -J250- 3145
1 2 1 Removing and installing electronically controlled damping control unit -J250-, Passat Saloon 3145
1 2 2 Removing and installing electronically controlled damping control unit -J250-, Passat Estate, Arteon 3146
1 3 Removing and installing front body acceleration senders -G341-/-G342- 3148
1 4 Removing and installing rear left body acceleration sender -G699- 3150
1 4 1 Removing and installing rear left body acceleration sender -G699-, Passat Saloon 3150
1 4 2 Removing and installing rear left body acceleration sender -G699-, Passat Estate 3151
1 4 3 Removing and installing rear left body acceleration sender -G699-, Arteon 3153
2 Vehicle level sender 3155
2 1 Assembly overview – front vehicle level senders 3155
2 2 Assembly overview – rear vehicle level senders 3156
2 2 1 Assembly overview – rear vehicle level senders, multi-link suspension, front-wheel drive 3156
2 2 2 Assembly overview – rear vehicle level senders, multi-link suspension, four-wheel drive 3157
2 3 Removing and installing front vehicle level senders -G78-/-G289- 3157
2 4 Removing and installing rear vehicle level senders -G76-/-G77- 3159
2 4 1 Removing and installing rear left vehicle level sender -G76-, multi-link suspension, front-wheel drive 3159
2 4 2 Removing and installing rear left vehicle level sender -G76-, multi-link suspension, four-wheel drive 3160
44 – Wheels, tyres, vehicle geometry 3162
1 Wheel alignment 3162
1 1 Notes for wheel alignment 3162
1 2 Conditions for testing 3163
1 3 Test preparations 3163
1 3 1 Test preparations, wheel alignment with no driver assist systems 3163
1 3 2 Test preparations, wheel alignment with driver assist systems 3165
1 4 Specifications for wheel alignment 3165
1 4 1 Specifications for wheel alignment, Passat Estate 3165
1 4 2 Specified values for wheel alignment, Arteon 3167
1 5 Wheel alignment procedure 3168
1 6 Necessity of wheel alignment 3170
1 7 Vehicle data sticker 3171
1 8 Adjusting camber at front wheels 3171
1 9 Adjusting camber on rear axle 3173
1 10 Adjusting toe at rear axle 3175
1 11 Adjusting front axle toe 3175
1 12 Wheel runout compensation 3177
1 13 Checking maximum steering wheel angle 3177
2 Adaptive cruise control 3179
2 1 Calibrating adaptive cruise control 3179
2 1 1 Calibrating adaptive cruise control, Passat, Passat Estate ► 08 2018 3179
2 1 2 Calibrating adaptive cruise control, Passat, Passat Estate, Arteon 08 2018 ► 3186
3 Front camera for assist systems 3191
3 1 Calibrating front camera for driver assist systems 3191
48 – Steering 3199
1 Steering wheel 3199
1 1 Assembly overview – steering wheel 3199
1 2 Removing and installing steering wheel 3199
2 Steering column 3202
2 1 Assembly overview – steering column 3202
2 2 Checking steering column for damage 3203
2 3 Handling and transporting steering column 3204
2 4 Removing and installing steering column 3205
2 5 Removing and installing control unit for electronic steering column lock -J764- 3215
3 Steering rack 3218
3 1 Assembly overview – steering rack 3218
3 1 1 Assembly overview – steering rack, left-hand drive 3218
3 1 2 Assembly overview – steering rack, right-hand drive 3220
3 1 3 Assembly overview – steering rack, track rods 3221
3 2 Removing and installing steering rack 3223
3 3 Removing and installing bellows 3234
3 4 Removing and installing track rod 3237
3 5 Removing and installing track rod ball joint 3242
3 6 Repairing steering rack 3244
3 6 1 Removing and installing threaded bush 3244
4 Sensors 3249
4 1 Removing and installing steering angle sender -G85- 3249
D4B804A300A 7 speed dual clutch gearbox 0DL 3250
00 – Technical data 3254
1 Safety information 3254
1 1 General safety provisions 3254
1 2 Safety measures when working on vehicles with a start/stop system 3255
1 3 Notes on tow-starting/towing 3255
1 4 Safety precautions when using testers and measuring instruments during a road test 3255
2 Identification 3257
2 1 Gearbox identification 3257
3 Repair instructions 3258
3 1 General information 3258
3 2 Rules for cleanliness 3259
3 3 General repair instructions 3259
3 4 Gaskets and seals 3260
3 5 Nuts and bolts 3261
4 Technical data 3262
4 1 Capacities 3262
5 Electrical components 3263
5 1 Overview of fitting locations – electrical components 3263
30 – Clutch 3264
1 Clutch 3264
1 1 Assembly overview – dual clutch 3264
1 2 Removing and installing clutch end cover 3265
1 3 Removing dual clutch 3270
1 4 Installing dual clutch 3273
34 – Controls, housing 3284
1 Mechatronic unit 3284
1 1 Removing and installing mechatronic unit for dual clutch gearbox -J743- (gearbox installed) 3284
1 2 Removing and installing gearbox input speed sender -G182- and oil temperature sender in multi-plate clutch -G509- up to gearbox date 05/15 3292
2 Bevel box 3294
2 1 Distinguishing between different types of bevel boxes 3294
2 2 Removing and installing bevel box 3295
2 2 1 Removing and installing bevel box, Passat 2015 ►, Tiguan 2016 ►, Arteon 2018 ► Arteon 2021 ►, Passat 2019 ►, vehicles with 2 0 l – 176 kW TDI with biturbo 3295
2 2 2 Removing and installing bevel box, Passat 2015 ►, Passat Estate 2019 ►, vehicles with petrol engine 3302
2 2 3 Removing and installing bevel box, Tiguan 2016 ►Tiguan 2021 ►, Tiguan RUS 2017 ►, Tiguan RUS 2021 ► 3313
2 3 Detaching bevel box from gearbox – gearbox removed 3324
3 Selector mechanism 3329
3 1 Assembly overview – selector mechanism 3329
3 1 1 Assembly overview – selector mechanism, Passat 2015 ►, Arteon 2018 ►, Arteon 2021 ►, Passat 2019 ► 3329
3 1 2 Assembly overview – selector mechanism, Tiguan 3330
3 2 Manual release from position P 3332
3 2 1 Emergency release from position P, Passat 2015 ►, Arteon 2018 ►, Arteon 2021 ►, Passat 2019 ► 3332
3 2 2 Manual release position P, Tiguan 3332
3 3 Removing and installing selector lever handle 3334
3 3 1 Removing and installing selector lever handle, Passat 2015 ►, Arteon 2018 ►, Arteon 2021 ►, Passat 2019 ► 3334
3 3 2 Removing and installing selector lever handle, Tiguan 3337
3 4 Moving push-button in the handle to installation position 3341
3 5 Removing and installing selector mechanism 3343
3 5 1 Removing and installing selector mechanism with selector lever cable 3343
3 5 2 Removing and installing selector mechanism without selector lever cable, Passat 2015 ►, Arteon 2018 ► 3345
3 5 3 Removing and installing selector mechanism without selector lever cable, Tiguan 3348
3 6 Removing and installing gear selector cable 3352
3 6 1 Removing and installing selector lever cable, Passat 2015 ►, Arteon 2018 ► 3352
3 6 2 Removing and installing selector lever cable, Tiguan 3354
3 7 Checking selector mechanism 3357
3 8 Checking and adjusting selector lever cable 3358
3 9 Renewing selector shaft seal 3360
4 Removing and installing gearbox 3363
4 1 Specified torques for gearbox 3363
4 1 1 Gearbox carrier to engine and bevel box 3363
4 2 Removing gearbox 3365
4 2 1 Removing gearbox, Passat 2015 ►, Passat Estate 2015 ►, Arteon 2018 ►, Arteon 2021 ►, Arteon Shooting Brake 2021 ►, Passat 2019 ►, Passat Estate 2019 ►, vehicles with 2 0 l – 176 kW TDI with biturbo 3365
4 2 2 Removing gearbox, Passat 2015 ►, Passat estate 2015 ►, Passat estate 2019 ► vehicles with petrol engine 3375
4 2 3 Removing gearbox, Tiguan 2016 ►, Tiguan 2021 ►, Tiguan RUS 2017 ►,Tiguan RUS 2021 ►, vehicles with 2 0 l – 105 kW, 110 kW, 130 kW, 140 kW diesel engine, all-wheel drive 3385
4 2 4 Removing gearbox, Tiguan 2016 ►, Tiguan 2021 ►, Tiguan RUS 2017 ►,Tiguan RUS 2021 ►, vehicles with petrol engine, all-wheel drive 3395
4 2 5 Removing gearbox, Tiguan 2016 ►, vehicles with diesel engine, front-wheel drive 3404
4 2 6 Removing gearbox, Tiguan 2016 ►, vehicles with 2 0 l – 176 kW TDI 3412
4 3 Installing gearbox 3422
5 Assembly mountings 3424
5 1 Assembly overview – assembly mountings 3424
6 Transporting gearbox 3428
7 Dismantling and assembling gearbox 3429
7 1 Assembly overview – gearbox 3429
7 1 1 Renewing bleeder 3432
7 1 2 Renewing sealing cap 3432
8 Securing to engine and gearbox support 3435
9 Gear oil circuit 3436
9 1 Removing and installing gear oil cooler 3436
9 2 Removing and installing gear oil filter 3438
10 Gear oil 3441
10 1 Checking gear oil level 3441
10 2 Draining and filling gear oil 3443
35 – Gears, shafts 3449
1 Currently, no repairs can be made to gears and shafts 3449
39 – Final drive – differential 3450
1 Gear oil 3450
1 1 Checking gear oil level 3450
1 1 1 Checking gear oil level, bevel box “0A6” 3450
1 1 2 Checking gear oil level, bevel box “0CP” 3451
1 2 Draining and filling gear oil 3452
1 2 1 Draining and filling gear oil, bevel box “0A6” 3452
1 2 2 Draining and filling gear oil, bevel box “0CP” 3455
2 Oil seals 3459
2 1 Overview of fitting locations – seals 3459
2 2 Renewing left seal 3459
2 2 1 Renewing oil seal for left flange shaft 3459
2 3 Renewing right seal 3463
2 3 1 Renewing seal on right of gearbox, front-wheel drive vehicles 3463
2 3 2 Renewing seal on right of gearbox, vehicles with all wheel drive 3465
3 Components of bevel box 3467
3 1 Assembly overview – components of bevel box 3467
3 1 1 Assembly overview – components of bevel box, 0A6 3467
3 1 2 Assembly overview – components of bevel box, 0CP 3469
3 2 Renewing bevel box seals 3471
3 2 1 Renewing left seal between bevel box and gearbox on bevel box 3471
3 2 2 Renewing seal on right of bevel box 3475
3 2 3 Renewing bevel box output flange seal, 0A6, bevel box removed 3480
3 2 4 Renewing bevel box output flange seal, 0CP, bevel box removed 3486
3 3 Renewing needle bearing (polygon bearing) for stub shaft 3492
D4B805CB339 Manual for Troubleshooting and Diagnosing Noises 3497
00 – Technical data 3503
1 Introduction 3503
2 Acoustic considerations during vehicle development 3504
2 1 Vibration insulation film 3504
2 2 Insulation 3505
3 General procedure for identifying noises 3507
3 1 General procedure 3507
3 2 Identifying a noise 3507
3 2 1 Localising origin of noise 3507
3 2 2 Identifying the type of noise 3508
3 2 3 Identifying the point in time when the noise occurs 3508
3 2 4 Identifying the noise by definition or designation 3508
3 3 Aid for localising noise by means of audio recordings (frequencies) 3508
3 3 1 Preparing an audio CD with downloaded files 3509
3 3 2 List of audio tracks 3509
3 3 3 Conditions for testing 3509
3 3 4 Conditions for performing the audio test 3510
3 4 Checklist 3510
4 Volkswagen equipment for localising noises 3514
4 1 Ultrasonic tester -VAG 1842- 3514
4 1 1 Design of the ultrasonic tester -VAG 1842- 3514
4 1 2 Example of procedure for identifying noises using ultrasound 3514
4 2 Borescope -VAS 6748A- 3518
4 2 1 Design of the borescope -VAS 6748A- 3518
4 2 2 Procedure for identifying noises using the borescope 3519
5 Attachments 3520
5 1 Checklist 3520
5 2 Designations for noises 3522
D4B805CD31D Manual on Localising the Ingress of Water 3523
00 – Technical data 3529
1 Introduction 3529
2 Causes 3530
2 1 Vehicle fluids 3530
2 2 External factors 3530
2 3 Components 3530
3 Localising water ingress 3534
3 1 Preparation by customer service advisor 3534
3 2 Work performed by the mechanic 3534
3 3 Examples of components causing water ingress 3535
4 Tools for localising ingress point 3537
5 Attachments 3538
5 1 Checklist 3538
D4B806B7058 Removed 6 speed manual gearbox 02S 3540
00 – Technical data 3544
1 Safety information 3544
2 Identification 3545
3 Repair instructions 3546
3 1 General repair instructions 3546
4 Technical data 3550
4 1 Allocation gearbox – engine 3550
4 2 Capacities 3550
5 Overview – power transmission 3551
6 Electrical components 3553
30 – Clutch 3554
1 Clutch mechanism 3554
1 1 Assembly overview – clutch release mechanism 3554
1 2 Repairing clutch release mechanism 3556
2 Clutch 3557
2 1 Assembly overview – clutch 3557
2 1 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 3557
2 1 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 3558
2 1 3 Assembly overview – clutch with simple flywheel 3558
2 2 Removing and installing clutch 3559
2 2 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 3559
2 2 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 3564
2 2 3 Removing and installing clutch in connection with simple flywheel 3570
34 – Controls, housing 3575
1 Selector mechanism 3575
2 Removing and installing gearbox 3576
3 Gearbox transport 3577
4 Dismantling and assembling gearbox 3578
4 1 Schematic overview – gearbox 3578
4 2 Dismantling and assembling gearbox; Assembly overview – gearbox 3579
4 3 Assembly overview – 5th and 6th gear 3580
4 4 Assembly overview – gearbox housing and selector mechanism 3583
4 5 Dismantling and assembling gearbox; Assembly overview – input shaft, output shafts, differential, selector rods 3585
4 6 Assembly overview – selector forks 3587
4 6 1 Assembly overview – selector forks, in gearboxes with reverse as synchromeshed gear 3587
4 6 2 Assembly overview – selector forks in gearboxes with locking collar on reverse gear 3589
4 7 Repairing selector forks 3590
4 8 Removing 5th and 6th gears 3595
4 9 Dismantling and assembling gearbox 3600
4 9 1 Dismantling gearbox housing with shafts and gear wheels 3600
4 9 2 Assembling gearbox housing with shafts and gear wheels 3610
4 10 Installing 5th/6th gear 3618
5 Gearbox housing, clutch housing 3627
5 1 Assembly overview – gearbox housing and clutch housing 3627
5 2 Gearbox housing, clutch housing; Assembly overview – gearbox housing cover 3630
5 3 Repairing gearbox housing 3630
5 3 1 Identifying output shaft bearing in gearbox housing 3631
5 3 2 Removing and installing roller bearing without retaining ring 3632
5 3 3 Removing and installing roller bearing with retaining ring 3634
5 4 Repairing gearbox housing cover 3637
6 Securing to engine and gearbox support 3640
7 Gear oil 3645
35 – Gears, shafts 3646
1 Input shaft 3646
1 1 Assembly overview – input shaft 3646
1 2 Dismantling and assembling input shaft 3648
1 3 Adjusting input shaft 3655
1 4 Renewing input shaft seal 3660
2 Output shaft 3663
2 1 Assembly overview – output shaft 3663
2 2 Dismantling and assembling output shaft 3666
2 3 Adjusting output shaft 3682
3 Reverse shaft 3689
3 1 Assembly overview – reverse shaft 3689
3 1 1 Assembly overview – reverse shaft with synchromeshed gear for reverse gear 3689
3 1 2 Assembly overview – reverse shaft with reverse gear locking collar 3690
3 2 Dismantling and assembling reverse shaft 3691
39 – Final drive – differential 3695
1 Oil seals 3695
1 1 Overview of fitting locations – oil seals 3695
2 Differential 3696
2 1 Assembly overview – differential 3696
2 2 Dismantling and assembling differential 3698
2 3 Adjusting differential 3703
3 Adjustment overview 3708
D4B806B8524 6 speed manual gearbox 02Q 0BB and 0FB removed 3709
00 – Technical data 3713
1 Safety information 3713
2 Identification 3714
3 Technical data 3715
3 1 Allocation gearbox – engine 3715
3 2 Capacities 3715
4 Overview – power transmission 3716
4 1 Overview – power transmission – front-wheel drive 3716
4 2 Overview – power transmission – all-wheel drive 3717
5 Electrical components 3720
6 Repair notes 3721
6 1 General repair instructions 3721
30 – Clutch 3725
1 Clutch mechanism 3725
1 1 Assembly overview – clutch release mechanism 3725
1 2 Removing and installing clutch slave cylinder together with release bearing 3727
1 3 Repairing clutch release mechanism 3729
2 Clutch 3731
2 1 Assembly overview – clutch 3731
2 1 1 Assembly overview – clutch in conjunction with Sachs dual-mass flywheel 3731
2 1 2 Assembly overview – clutch in conjunction with LuK dual-mass flywheel 3732
2 1 3 Assembly overview – clutch with simple flywheel 3733
2 2 Removing and installing clutch 3734
2 2 1 Removing and installing clutch in conjunction with Sachs dual-mass flywheel 3734
2 2 2 Removing and installing clutch in conjunction with LuK dual-mass flywheel 3741
2 2 3 Removing and installing clutch in connection with simple flywheel 3747
34 – Controls, housing 3752
1 Selector mechanism 3752
2 Removing and installing gearbox 3753
3 Bevel box 3754
3 1 Distinguishing between different types of bevel boxes 3754
3 2 Removing bevel box 3754
3 3 Installing bevel box 3754
4 Front differential lock 3755
5 Transporting gearbox 3756
5 1 Transporting manual gearbox 3756
5 2 Transporting front differential lock 3757
6 Gear oil 3758
7 Securing to engine and gearbox support 3759
7 1 Installing manual gearbox to engine and gearbox support 3759
7 2 Installing bevel box or front differential lock to engine and gearbox support 3760
8 Dismantling and assembling gearbox 3762
8 1 Schematic overview – gearbox 3762
8 1 1 Schematic overview – gearbox, front-wheel drive 3762
8 1 2 Schematic overview – front differential lock 3763
8 1 3 Schematic overview – gearbox, all-wheel drive 3764
8 2 Assembly overview – gearbox 3765
8 2 1 Assembly overview – gearbox with front-wheel drive 3765
8 2 2 Assembly overview – gearbox with four-wheel drive, gearbox with front-wheel drive and front differential lock 3766
8 3 Assembly overview – gearbox housing and selector mechanism 3767
8 4 Assembly overview – shafts, differential, selector mechanism 3770
8 4 1 Assembly overview – shafts, differential, selector mechanism, front-wheel drive 3770
8 4 2 Assembly overview – shafts, differential, gear selector, all-wheel drive and front-wheel drive with front differential lock 3772
8 5 Assembly overview – selector forks 3774
8 6 Dismantling and assembling gearbox 3775
8 6 1 Dismantling gearbox 3775
8 6 2 Assembling gearbox 3788
9 Gearbox housing, clutch housing 3800
9 1 Assembly overview – gearbox housing 3800
9 2 Assembly overview – clutch housing 3802
9 3 Repairing gearbox housing 3804
9 4 Repairing clutch housing 3814
35 – Gears, shafts 3817
1 Input shaft 3817
1 1 Assembly overview – input shaft 3817
1 2 Dismantling and assembling input shaft 3818
1 3 Renewing input shaft seal 3824
2 Output shaft 3826
2 1 Assembly overview – output shaft 3826
2 1 1 Assembly overview – output shaft for 1st to 4th gears 3826
2 1 2 Assembly overview – output shaft for 5th, 6th and reverse gears 3831
2 2 Dismantling and assembling output shaft 3833
2 2 1 Dismantling and assembling output shaft for 1st to 4th gears 3833
2 2 2 Dismantling and assembling output shaft for 5th, 6th and reverse gears 3850
2 3 Adjusting output shaft 3862
2 3 1 Adjusting output shaft for 1st to 4th gears 3862
2 3 2 Adjusting output shaft for 5th, 6th and reverse gears 3868
39 – Final drive – differential 3874
1 Seals 3874
1 1 Overview of fitting locations – oil seals 3874
2 Differential 3877
2 1 Assembly overview – differential 3877
2 1 1 Assembly overview – differential, front-wheel drive 3877
2 1 2 Assembly overview – differential, four-wheel drive and front-wheel drive with front differential lock 3879
2 2 Dismantling and assembling differential 3882
2 2 1 Dismantling and assembling differential, front-wheel drive 3882
2 2 2 Dismantling and assembling differential, four-wheel drive, front-wheel drive with front differential lock 3889
2 3 Adjusting differential 3898
3 Adjustment overview 3903
4 Components of bevel box 3904
4 1 Assembly overview – components of bevel box 3904
4 1 1 Assembly overview – components of bevel box, “0AV” 3904
4 1 2 Assembly overview – components of bevel box, “0CN” 3907
4 2 Renewing bevel box seals 3909
4 2 1 Renewing seal between gearbox and bevel box with bevel box removed 3910
4 2 2 Renewing output flange oil seal, bevel box “0AV” (bevel box removed) 3911
4 2 3 Renewing output flange oil seal, bevel box “0CN” (bevel box removed) 3926
4 3 Renewing output flange and redetermining thickness of shim 3937
5 Components of front differential lock 3939
5 1 Assembly overview – components of front differential lock 3939
5 2 Checking function 3941
5 3 Renewing seals for front differential lock 3941
5 3 1 Renewing seal between front differential lock and manual gearbox on front differential lock 3941
5 3 2 Renewing oil seal for right flange shaft within front differential lock 3943
5 4 Renewing ball bearing for flange shaft 3947
6 Gear oil 3952
7 Oil for front differential lock 3953
D4B8048F894 6 speed dual clutch gearbox 0DD hybrid vehicles 3954
00 – Technical data 3958
1 Safety information 3958
1 1 Safety measures for working on vehicles with high-voltage system 3958
1 1 1 General safety precautions when working on a high-voltage system 3958
1 1 2 Safety precautions for work on a high-voltage system for which the high-voltage system must be de-energised 3959
1 1 3 Safety precautions when re-energising high-voltage system 3960
1 1 4 Safety precautions when working in the vicinity of high-voltage components 3960
1 1 5 Safety precautions for work on a high-voltage system for which the ignition must be switched on 3961
1 1 6 Safety precautions for work on a high-voltage system for which the ignition must not be switched on 3962
1 2 General safety provisions 3962
1 3 Safety measures when working on vehicles with a start/stop system 3963
1 4 Safety precautions when using testers and measuring instruments during a road test 3963
1 5 Safety precautions when tow-starting or towing 3963
2 Identification 3964
2 1 Gearbox identification 3964
3 Repair instructions 3965
3 1 General information 3965
3 2 Rules for cleanliness 3966
3 3 General repair instructions 3966
3 4 Safety functions of gearbox control unit 3967
4 Technical data 3969
4 1 Capacities 3969
30 – Clutch 3970
1 Clutch 3970
1 1 Assembly overview – dual clutch 3970
1 2 Renewing input shaft seal 3970
2 Clutch mechanism 3972
2 1 Assembly overview – clutch engagement 3972
2 2 Removing and installing clutch engagement 3972
34 – Controls, housing 3975
1 Mechatronic unit 3975
1 1 Assembly overview – mechatronic unit 3975
1 2 Removing and installing sump 3977
1 3 Removing and installing mechatronic unit 3980
2 Selector mechanism 3986
2 1 Assembly overview – selector mechanism 3986
2 1 1 Assembly overview- selector mechanism, Golf 2013 ►, Golf 2017 ► 3986
2 1 2 Assembly overview- selector mechanism, Golf 2020 ► 3988
2 1 3 Assembly overview – selector mechanism, vehicles up to June 2017 3990
2 1 4 Assembly overview – selector mechanism, vehicles as of July 2017 ► 3992
2 2 Manual release from position P 3994
2 2 1 Emergency release from position P, Golf 2013 ►, Golf 2017 ► 3994
2 2 2 Manual release from position P, Golf 2020 ► 3995
2 2 3 Manual release from P position, Passat 2015 ►, Passat Estate 2015 ►, Passat 2019 ►, Passat Estate 2019 ►, Arteon 2021 ►, Arteon Shooting Brake 2021 ► 3997
2 3 Removing and installing selector lever handle 3998
2 3 1 Removing and installing selector lever handle, Golf 2013 ►, Golf 2017 ► 3998
2 3 2 Removing and installing selector lever handle, Passat 2015 ►, Passat Estate 2015 ►, Passat 2019 ►, Passat Estate 2019 ►, Arteon 2021 ►, Arteon Shooting Brake 2021 ►, Tiguan 2021 ► 4001
2 4 Moving push-button in the handle to installation position 4004
2 5 Removing and installing selector mechanism 4006
2 5 1 Removing and installing selector mechanism with selector lever cable 4006
2 5 2 Removing and installing selector mechanism without selector lever cable, Golf 2013 ►, Golf 2017 ► 4009
2 5 3 Removing and installing selector mechanism, Golf 2020 4013
2 5 4 Removing and installing selector mechanism without selector lever cable, Passat 2015 ►, Passat Variant 2015 ► 4018
2 6 Removing and installing gear selector cable 4021
2 6 1 Removing and installing final drive, Golf 2013 ►, Golf 2017 ► 4021
2 6 2 Removing and installing selector lever cable, Passat 2015 ►, Passat Variant 2015 ► 4025
2 7 Checking selector mechanism 4029
2 7 1 Checking selector mechanism, Arteon 2021 ►, Arteon Shooting Brake 2021 ►, Golf 2013 ►, Golf 2017 ►, Passat 2015 ►, Passat 2019 ►, Passat Estate 2015 ►, Passat Estate 2019 ►, Tiguan 2021 ► 4029
2 7 2 Checking selector mechanism, Golf 2020 ► 4033
2 8 Checking and adjusting selector lever cable 4035
2 8 1 Checking and adjusting selector lever cable, Arteon 2021 ►, Arteon Shooting Brake 2021 ►, Golf 2013 ►, Golf 2017 ►, Passat 2015 ►, Passat 2019 ►, Passat Estate 2015 ►, Passat Estate 2019 ►, Tiguan 2021 ► 4035
2 8 2 Adjusting selector lever cable, Golf 2020 ► 4038
2 9 Renewing selector shaft seal 4039
2 9 1 Renewing selector shaft seal, Arteon 2021 ►, Arteon Shooting Brake 2021 ►, Golf 2013 ►, Golf 2017 ►, Passat 2015 ►, Passat 2019 ►, Passat Estate 2015 ►, Passat Estate 2019 ►, Tiguan 2021 ► 4040
2 9 2 Renewing selector shaft oil seal, Golf 2020 ► 4044
3 Removing and installing gearbox 4051
3 1 Removing gearbox 4051
3 2 Installing gearbox 4051
3 2 1 Installing gearbox, Arteon 2021 ►, Arteon Shooting Brake 2021 ►, Golf 2013 ►, Golf 2017 ►, Passat 2015 ►, Passat 2019 ►, Passat Estate 2015 ►, Passat Estate 2019 ►, Tiguan 2021 ► 4051
3 2 2 Installing gearbox, Golf 2020 ► 4052
3 3 Specified torques for gearbox 4054
4 Assembly mountings 4055
4 1 Assembly overview – assembly mountings 4055
5 Transporting gearbox 4058
6 Gear oil circuit 4060
6 1 Assembly overview – gear oil circuit 4060
6 2 Removing and installing gear oil cooler 4060
6 3 Removing and installing gear oil filter 4063
7 Gear oil 4065
7 1 Overview of fitting locations – oil drain and inspection plugs 4065
7 2 Checking gear oil level 4065
7 3 Draining and filling gear oil 4071
7 4 Filling with gear oil after mechatronic unit has been renewed 4076
8 Dismantling and assembling gearbox 4079
8 1 System overview – gearbox 4079
8 2 Assembly overview – gearbox 4079
8 2 1 Assembly overview – gearbox, Arteon 2021 ►, Arteon Shooting Brake 2021 ►, Golf 2013 ►, Golf 2017 ►, Passat 2015 ►, Passat 2019 ►, Passat Estate 2015 ►, Passat Estate 2019 ►, Tiguan 2021 ► 4080
8 2 2 Assembly overview – gearbox, Golf 2020 ► 4082
8 3 Assembly overview – hybrid module 4084
8 4 Removing hybrid module 4084
8 5 Renewing hybrid module 4090
8 6 Installing hybrid module 4096
8 7 Removing and installing rotor position sensor and temperature sender 4100
8 8 Removing and installing cap 4104
8 8 1 Removing and installing pressed-in cap, Arteon 2021 , Arteon Shooting Brake 2021 ►, Golf 2013 ►, Golf 2017 ►, Passat 2015 ►, Passat 2019 ►, Passat Estate 2015 ►, Passat Estate 2019 ►, Tiguan 2021 ► 4104
8 8 2 Removing and installing screwed-in cap, Arteon 2021 ►, Arteon Shooting Brake 2021 ►, Golf 2013 ►, Golf 2017 ►, Passat 2015 ►, Passat 2019 ►, Passat Estate 2015 ►, Passat Estate 2019 ►, Tiguan 2021 ► 4106
8 8 3 Removing and installing clamped cap, Golf 2020 ► 4107
8 8 4 Removing and installing screwed cap, Golf 2020 ► 4109
35 – Gears, shafts 4110
1 Dismantling and assembling gears and shafts 4110
39 – Final drive – differential 4111
1 Oil seals 4111
1 1 Overview of fitting locations – oil seals 4111
1 2 Renewing left seal 4111
D4B8057EB0C 4 cylinder direct injection engine (1 4 l engine 4 V EA 211 turbocharger hybrid) 4115
00 – Technical data 4123
1 Safety information 4123
1 1 Safety precautions when working on high-voltage system 4123
1 2 Safety precautions when working in the vicinity of high-voltage components 4124
1 3 Safety regulations for working on fuel supply 4124
1 4 Safety precautions when using testing and measuring instruments during a road test 4124
1 5 Safety precautions when working on ignition system 4125
1 6 Safety precautions when working on the cooling system 4125
2 Identification 4126
2 1 Engine number/engine data 4126
3 Repair notes 4128
3 1 Rules for cleanliness 4128
3 2 Foreign objects in engine 4128
3 3 Contact corrosion 4128
3 4 Routing and attachment of lines 4129
3 5 Fitting radiator and condensers 4129
3 6 Checking vacuum system 4129
4 Hazard classification of high-voltage system 4130
10 – Removing and installing engine 4138
1 Removing and installing engine 4138
1 1 Removing engine 4138
1 2 Supporting engine and gearbox using scissor-type assembly platform -VAS 6131 B- 4147
1 3 Separating engine and gearbox 4154
1 4 Securing engine on engine and gearbox support 4157
1 5 Installing engine 4159
2 Assembly mountings 4164
2 1 Assembly overview – assembly mountings 4164
2 2 Removing and installing engine mounting 4167
2 3 Removing and installing gearbox mounting 4168
2 4 Removing and installing pendulum support 4169
2 5 Supporting engine in installation position 4170
2 5 1 Supporting engine in installation position, Passat, when working on gearbox-mounting side 4170
2 5 2 Supporting engine in installation position, Passat, when working on engine-mounting side 4177
2 5 3 Taking up weight of engine in installation position, Golf, Tiguan, Arteon, Arteon Sh Br, when working on gearbox-mounting side 4181
2 5 4 Taking up weight of engine in installation position, Golf, Tiguan, Arteon, Arteon Sh Br, when working on engine-mounting side 4185
2 6 Checking adjustment of assembly mountings 4189
2 7 Adjusting assembly mountings 4191
3 Engine cover panel 4193
3 1 Removing and installing engine cover 4193
13 – Crankshaft group 4194
1 Cylinder block (pulley end) 4194
1 1 Assembly overview – sealing flange, vibration-damper end 4194
1 2 Removing and installing engine support 4196
1 3 Removing and installing vibration damper 4197
1 4 Renewing crankshaft oil seal – belt pulley end 4199
1 5 Removing and installing sealing flange on pulley end 4202
2 Cylinder block, gearbox end 4206
2 1 Assembly overview – cylinder block, gearbox end 4206
2 2 Removing and installing flywheel 4208
2 3 Removing and installing sealing flange on gearbox side 4210
3 Crankshaft 4223
3 1 Crankshaft dimensions 4223
3 2 Measuring axial clearance of crankshaft 4223
4 Pistons and conrods 4225
4 1 Assembly overview – pistons and conrods 4225
4 2 Removing and installing pistons 4229
4 3 Checking pistons and cylinder bores 4230
4 4 Checking radial clearance of conrods 4232
4 5 Removing and installing oil spray jets 4233
4 6 Setting piston to TDC position 4234
15 – Cylinder head, valve gear 4240
1 Cylinder head 4240
1 1 Assembly overview – cylinder head 4240
1 2 Assembly overview – camshaft housing 4242
1 3 Removing and installing cylinder head 4245
1 4 Removing and installing camshaft housing 4251
1 4 1 Removing and installing camshaft housing 4251
1 4 2 Removing and installing camshaft housing when removing cylinder head 4256
1 5 Checking compression 4263
2 Toothed belt drive 4266
2 1 Assembly overview – toothed belt cover 4266
2 2 Assembly overview – toothed belt 4266
2 3 Removing and installing toothed belt guard 4268
2 3 1 Removing and installing upper toothed belt guard 4268
2 3 2 Removing and installing lower toothed belt guard 4268
2 4 Preassembling and installing valve timing tool 4269
2 4 1 Preassembling test tool -VAS 611 007- 4269
2 4 2 Installing test tool -VAS 611 007- 4272
2 4 3 Teaching-in test tool -VAS 611 007- electronically and performing basic setting 4275
2 5 Removing and installing toothed belt 4278
2 6 Checking valve timing 4284
2 7 Adjusting valve timing 4286
2 8 Removing toothed belt from camshaft 4297
3 Valve gear 4303
3 1 Assembly overview – valve gear 4303
3 2 Measuring axial play of camshaft 4305
3 3 Removing and installing camshaft oil seal 4306
3 3 1 Removing and installing inlet camshaft oil seal 4306
3 3 2 Removing and installing exhaust camshaft oil seal, pulley end 4309
3 3 3 Removing and installing exhaust camshaft oil seal, gearbox end 4311
3 4 Removing and installing camshaft adjuster 4313
3 4 1 Removing and installing camshaft adjuster on inlet side 4313
3 4 2 Removing and installing camshaft adjuster, exhaust side 4319
3 5 Removing and installing camshaft control valve 1 -N205- 4323
3 6 Removing and installing exhaust camshaft control valve 1 -N318- 4324
3 7 Removing and installing valve stem seals 4325
3 7 1 Removing and installing valve stem seals (cylinder head installed) 4325
3 7 2 Removing and installing valve stem seals (cylinder head removed) 4330
4 Inlet and exhaust valves 4335
4 1 Checking valve guides 4335
4 2 Checking valves 4336
4 3 Valve dimensions 4336
17 – Lubrication 4337
1 Sump, oil pump 4337
1 1 Assembly overview – sump/oil pump 4337
1 2 Engine oil: 4341
1 3 Removing and installing lower part of sump 4341
1 4 Removing and installing upper part of sump 4347
1 5 Removing and installing oil pump 4352
1 6 Removing and installing oil level and oil temperature sender -G266- 4354
2 Engine oil cooler 4355
2 1 Assembly overview – engine oil cooler 4355
2 2 Removing and installing engine oil cooler 4355
3 Crankcase ventilation 4357
3 1 Assembly overview – crankcase breather system 4357
3 2 Removing and installing oil separator 4358
4 Oil filter, oil pressure switch 4362
4 1 Assembly overview – oil filter/oil pressure switch 4362
4 2 Removing and installing oil pressure switch -F22- 4364
4 3 Removing and installing oil pressure switch for reduced oil pressure -F378- 4366
4 4 Removing and installing oil pressure regulating valve -N428- 4368
4 5 Checking oil pressure 4368
19 – Cooling 4370
1 Cooling system/coolant 4370
1 1 Connection diagram – coolant hoses 4370
1 1 1 Connection diagram – coolant hoses 4370
1 1 2 Connection diagram – coolant hoses, Golf 08 2020► 4372
1 1 3 Coolant hose schematic diagram, high-voltage system 4374
1 1 4 Connection diagram – coolant hoses high-voltage system, Passat 10 2020►, Tiguan, Arteon, Arteon Sh Br 4376
1 2 Checking cooling system for leaks 4378
1 2 1 Checking cooling system for leaks 4378
1 2 2 Checking cooling system of high-voltage system for leaks 4381
1 3 Draining and adding coolant 4392
1 4 Draining and adding coolant, high-voltage system 4399
1 4 1 Draining coolant, front 4399
1 4 2 Draining coolant, high-voltage battery 4400
1 4 3 Filling with coolant 4402
1 5 Checking filling quality, high-voltage system 4408
2 Coolant pump, regulation of cooling system 4411
2 1 Assembly overview – coolant pump, thermostat 4411
2 2 Overview of fitting locations – electric coolant pumps 4414
2 3 Assembly overview – electric coolant pump 4415
2 4 Assembly overview – coolant temperature sender 4417
2 5 Assembly overview – coolant valves 4417
2 6 Removing and installing electric coolant pump 4419
2 6 1 Removing and installing coolant pump for high temperature circuit -V467- 4419
2 6 2 Removing and installing coolant pump for low-temperature circuit -V468- 4421
2 6 3 Removing and installing coolant circulation pump before power and control electronics for electric drive -V508-, Passat, Golf 08 2020►, Tiguan, Arteon, Arteon Sh Br 4423
2 6 4 Removing and installing coolant circulation pump before power and control electronics for electric drive -V508-, Golf ►08 2020 4425
2 6 5 Removing and installing coolant pump for high-voltage battery -V590-, Passat 4428
2 6 6 Removing and installing coolant pump for high-voltage battery -V590-, Golf, Tiguan, Arteon, Arteon Sh Br 4430
2 7 Removing and installing coolant pump 4433
2 8 Removing and installing thermostat 4436
2 8 1 Removing and installing thermostat for main coolant circuit (radiator) 4436
2 8 2 Removing and installing thermostat for coolant circuit of cylinder block 4439
2 9 Removing and installing toothed belt pulley for coolant pump 4440
2 10 Removing and installing coolant temperature sender -G62- 4442
2 11 Removing and installing radiator outlet coolant temperature sender -G83- 4443
2 12 Removing and installing coolant valves 4445
2 12 1 Removing and installing coolant valve for gearbox -N488- 4445
2 12 2 Removing and installing coolant changeover valve 1 -N632- 4446
2 12 3 Removing and installing coolant changeover valve 2 -N633- 4448
2 12 4 Removing and installing coolant valve for high-voltage battery -N688- 4449
2 13 Removing and installing coolant temperature sender for heater -G241- 4452
2 14 Removing and installing engine temperature sender 2 -G788- 4453
3 Coolant pipes 4455
3 1 Assembly overview – coolant pipes 4455
3 1 1 Assembly overview – coolant pipes, Passat, Golf ►08 2020, Tiguan, Arteon, Arteon Sh Br 4455
3 1 2 Assembly overview – coolant pipes, Golf 08 2020► 4455
3 2 Removing and installing coolant pipes 4456
3 2 1 Removing and installing front coolant pipes, Passat, Golf ►08 2020, Tiguan, Arteon, Arteon Sh Br 4456
3 2 2 Removing and installing front coolant pipes, Golf 08 2020► 4458
3 2 3 Removing and installing left coolant pipes 4459
3 2 4 Removing and installing left coolant pipes for cooling high-voltage system 4461
4 Radiator, radiator fan 4465
4 1 Assembly overview – radiator/radiator fan 4465
4 2 Assembly overview – radiator cowl and radiator fan 4468
4 3 Removing and installing radiator 4469
4 3 1 Removing and installing radiator, Passat, Arteon, Arteon Sh Br 4469
4 3 2 Removing and installing radiator, Golf ►08 2020 4475
4 3 3 Removing and installing radiator, Golf 08 2020►, Tiguan 4480
4 4 Removing and installing radiator cowl 4484
4 4 1 Removing and installing radiator cowl, Passat, Arteon, Arteon Sh Br 4484
4 4 2 Removing and installing radiator cowl, Golf ►08 2020 4487
4 4 3 Removing and installing radiator cowl, Golf 08 2020►, Tiguan 4489
4 5 Removing and installing radiator fan -V7- 4491
21 – Turbocharging/supercharging 4492
1 Turbocharger 4492
1 1 Assembly overview – turbocharger 4492
1 1 1 Assembly overview – turbocharger, version 1 4492
1 1 2 Assembly overview – turbocharger, version 2 4494
1 2 Removing and installing turbocharger 4497
1 3 Removing and installing charge pressure positioner -V465- 4503
1 3 1 Removing and installing charge pressure positioner -V465-, version 1 4503
1 3 2 Removing and installing charge pressure positioner -V465-, version 2 4504
1 4 Removing and installing connection for turbocharger 4506
2 Charge air system 4510
2 1 Assembly overview – charge air system 4510
2 2 Removing and installing charge pressure sender -GX26- 4512
2 3 Removing and installing charge air cooler 4513
2 4 Checking charge air system for leaks 4514
2 5 Removing and installing air intake pipe 4516
24 – Mixture preparation – injection 4519
1 Injection system 4519
1 1 Overview of fitting locations – injection system 4519
1 1 1 Overview of fitting locations – engine compartment 4519
1 1 2 Overview of fitting locations on engine (from above) 4523
1 1 3 Overview of fitting locations – front view of engine 4524
1 1 4 Overview of fitting locations – rear view of engine 4525
2 Injectors 4527
2 1 Assembly overview – fuel rail with injectors 4527
2 1 1 Assembly overview – fuel rail with injectors, vehicles without particulate filter 4527
2 1 2 Assembly overview – fuel rail with injectors, vehicles with particulate filter 4529
2 2 Removing and installing fuel rail 4531
2 3 Removing and installing injectors 4532
2 3 1 Removing and installing injectors, vehicles without particulate filter 4532
2 3 2 Removing and installing injectors, vehicles with particulate filter 4539
2 4 Cleaning injectors 4546
3 Air filter 4549
3 1 Assembly overview – air filter housing 4549
3 2 Removing and installing air filter housing 4551
3 3 Removing and installing resonator for intake air 4552
4 Intake manifold 4554
4 1 Assembly overview – intake manifold 4554
4 2 Removing and installing intake manifold 4556
4 3 Removing and installing throttle valve module -GX3- 4559
4 4 Cleaning throttle valve module -GX3- 4560
5 Senders and sensors 4562
5 1 Removing and installing fuel pressure sender -G247- 4562
5 2 Checking fuel pressure sender -G247- 4563
5 2 1 Checking fuel pressure sender -G247-, using pressure sensor tester -VAS 6394- and vehicle diagnostic tester 4563
5 2 2 Checking fuel pressure sender -G247-, using vehicle diagnostic tester 4565
5 3 Removing and installing intake manifold sender -GX9- 4567
5 4 Removing and installing pressure differential sender for particulate filter -G1037- 4568
6 Engine control unit 4570
6 1 Removing and installing engine control unit -J623- 4570
6 1 1 Removing and installing engine control unit -J623- without protective housing 4570
6 1 2 Removing and installing engine (motor) control unit -J623- with protective housing 4571
7 High-pressure pump 4575
7 1 Assembly overview – high-pressure pump 4575
7 1 1 Assembly overview – high-pressure pump, version 1 4575
7 1 2 Assembly overview – high-pressure pump, version 2 4578
7 1 3 Assembly overview – high-pressure pump, version 3 4580
7 2 Removing and installing high-pressure pump 4582
7 2 1 Removing and installing high-pressure pump, version 1 4582
7 2 2 Removing and installing high-pressure pump, version 2 4583
7 3 Removing and installing high-pressure pipe 4585
8 Lambda probe 4587
8 1 Assembly overview – Lambda probe 4587
8 1 1 Assembly overview – Lambda probe 4587
8 1 2 Assembly overview – Lambda probe, vehicles with particulate filter 4588
8 2 Removing and installing Lambda probe 4590
8 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 4590
8 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 4591
8 2 3 Removing and installing lambda probe 1 after catalytic converter -GX7-, vehicles with particulate filter 4593
26 – Exhaust system 4595
1 Exhaust pipes and silencers 4595
1 1 Assembly overview – silencers 4595
1 1 1 Assembly overview – silencer, Passat, Golf 08 2020►, Arteon, Arteon Sh Br 4595
1 1 2 Assembly overview – silencers, Golf ►08 2020 4597
1 1 3 Assembly overview – silencers, Tiguan 4599
1 2 Separating exhaust pipes from silencers 4600
1 3 Removing and installing silencer 4601
1 3 1 Removing and installing silencer, Passat, Golf 08 2020►, Tiguan, Arteon, Arteon Sh Br 4601
1 3 2 Removing and installing silencer, Golf ►08 2020 4603
1 4 Installation position of clamp 4604
1 5 Aligning exhaust system free of stress 4604
1 6 Checking exhaust system for leaks 4605
2 Emission control 4606
2 1 Assembly overview – emission control 4606
2 1 1 Assembly overview – emission control 4606
2 1 2 Assembly overview – emission control, vehicles with particulate filter, Golf, Passat, Arteon, Arteon Sh Br 4608
2 1 3 Assembly overview – emission control, vehicles with particulate filter, Tiguan 4610
2 1 4 Assembly overview – bracket and pipes for pressure differential sender for particulate filter -G1037- 4612
2 2 Removing and installing catalytic converter 4614
2 2 1 Removing and installing catalytic converter 4614
2 2 2 Removing and installing catalytic converter, vehicles with no particulate filter 4618
2 3 Removing and installing particulate filter 4623
3 Exhaust gas temperature regulation 4624
3 1 Assembly overview – exhaust gas temperature regulation 4624
3 2 Removing and installing parts of exhaust gas temperature regulation 4626
3 2 1 Removing and installing temperature sender before particulate filter -G506- 4626
3 2 2 Removing and installing temperature sender after particulate filter -G527- 4627
28 – Ignition system 4629
1 Ignition system 4629
1 1 Assembly overview – ignition system 4629
1 2 Removing and installing ignition coils with output stage 4631
1 3 Removing and installing knock sensor 1 -G61- 4634
1 4 Removing and installing Hall sender 4635
1 4 1 Removing and installing Hall sender -G40- 4635
1 4 2 Removing and installing Hall sender 3 -G300- 4636
1 5 Removing and installing engine speed sender -G28- 4637
93 – Electric drive systems 4639
1 Warning stickers 4639
1 1 Checking warning stickers 4639
2 High-voltage components 4646
2 1 Overview of fitting locations – high-voltage components 4646
2 1 1 Overview of fitting locations – high-voltage components, Passat, Golf ►08 2020 4646
2 1 2 Overview of fitting locations – high-voltage components, Golf 08 2020►, Tiguan 4647
3 High-voltage battery unit 4649
3 1 Assembly overview – high-voltage battery 4649
3 1 1 Assembly overview – high-voltage battery, Golf ►08 2020, Passat ►09 2019 4649
3 1 2 Assembly overview – high-voltage battery, Passat 09 2019►, Golf 08 2020►, Tiguan, Arteon 4651
3 2 Visual inspection of high-voltage battery 1 -AX2- 4651
3 3 Removing and installing high-voltage battery 1 -AX2- 4652
3 4 Leakage test of high-voltage battery 1 -AX2- 4659
3 4 1 Leakage test of high-voltage battery 1 -AX2-, Golf 4659
3 4 2 Leakage test of high-voltage battery 1 -AX2-, Passat, Golf 08 2020►, Tiguan, Arteon 4660
3 5 Searching for leaks from high-voltage battery 4660
3 6 Raising high-voltage battery 1 -AX2- 4660
3 7 Removing and installing battery regulation control unit -J840- 4663
3 7 1 Removing and installing battery regulation control unit -J840-, Passat ►09 2019 4663
3 7 2 Removing and installing battery regulation control unit -J840-, Passat 09 2019►, Golf 08 2020►, Tiguan, Arteon 4666
3 7 3 Removing and installing battery regulation control unit -J840-, Golf ►08 2020 4667
4 Repairing high-voltage battery unit 4672
4 1 Overview of fitting locations – high-voltage battery 1 -AX2- 4672
4 1 1 Overview of fitting locations – high-voltage battery 1 -AX2-, Golf ►08 2020 4673
4 1 2 Overview of fitting locations – high-voltage battery 1 -AX2-, Passat ►09 2019 4673
4 1 3 Overview of fitting locations – high-voltage battery 1 -AX2-, Passat 09 2019►, Golf 08 2020►, Tiguan, Arteon 4674
4 2 Overview of fitting locations – battery modules 4675
4 2 1 Overview of fitting locations – battery modules, Golf ►08 2020 4675
4 2 2 Overview of fitting locations – battery modules, Passat ►09 2019 4676
4 2 3 Overview of fitting locations – battery modules, Passat 09 2019►, Golf 08 2020►, Tiguan, Arteon 4677
4 3 Overview of fitting locations – high-voltage connector 4678
4 3 1 Overview of fitting locations – high-voltage connector, Golf ►08 2020 4678
4 3 2 Overview of fitting locations – high-voltage connector, Passat ►09 2019 4679
4 3 3 Overview of fitting locations – high-voltage connectors, Passat 09 2019►, Golf 08 2020►, Tiguan, Arteon 4681
4 4 Assembly overview – battery housing 4683
4 4 1 Assembly overview – battery housing, ►Golf 08 2020 4683
4 4 2 Assembly overview – battery housing, Passat, Golf 08 2020►, Tiguan, Arteon 4684
4 5 Assembly overview – switching unit for high-voltage battery SX6 4686
4 5 1 Assembly overview – switching unit for high-voltage battery SX6, Golf ►08 2020 4686
4 5 2 Assembly overview – switching unit for high-voltage battery SX6, Passat ►09 2019 4687
4 5 3 Assembly overview – switching unit for high-voltage battery SX6, Passat 09 2019►, Golf 08 2020►, Tiguan, Arteon 4688
4 6 Assembly overview – battery module assembly 4689
4 6 1 Assembly overview – battery module assembly, Golf ►08 2020 4689
4 6 2 Assembly overview – battery module assembly, Passat, Golf 08 2020►, Tiguan, Arteon 4690
4 7 Assembly overview – battery modules 4692
4 8 Assembly overview – high voltage system connection 4693
4 8 1 Assembly overview – high voltage system connection, Golf ►08 2020 4693
4 8 2 Assembly overview – high-voltage system connection, Passat, Golf 08 2020►, Tiguan, Arteon 4694
4 9 Assembly overview – cooling system high-voltage battery 1 -AX2- 4695
4 10 Assembly overview – wiring harnesses 4696
4 11 Diagnosis of high-voltage battery 1 -AX2- 4698
4 12 Leakage test in cooling system of high-voltage battery 1 -AX2- 4698
4 13 Charging and discharging battery modules 4700
4 13 1 Charging and discharging battery modules, Golf ►08 2020 4700
4 13 2 Charging and discharging battery modules, Passat, Golf 08 2020►, Tiguan, Arteon 4701
4 14 Opening high-voltage battery 1 -AX2- 4702
4 14 1 Opening high-voltage battery 1 -AX2-, Golf ►08 2020 4702
4 14 2 Opening high-voltage battery 1 -AX2-, Passat, Golf 08 2020►, Tiguan, Arteon 4705
4 15 Voltage and insulation measurement 4706
4 16 Removing and installing switching unit for high-voltage battery -SX6- 4708
4 16 1 Removing and installing switching unit for high-voltage battery -SX6-, Golf ►08 2020 4708
4 16 2 Removing and installing switching unit for high-voltage battery -SX6-, Passat ►09 2019 4712
4 16 3 Removing and installing switching unit for high-voltage battery -SX6-, Passat 09 2019►, Golf 08 2020►, Tiguan, Arteon 4716
4 17 Removing and installing wiring harness for high-voltage battery 1 -AX2- 4718
4 17 1 Removing and installing wiring harness for high-voltage battery 1 -AX2-, Passat ►09 2019 4718
4 17 2 Removing and installing wiring harness for high-voltage battery 1 -AX2-, Passat 09 2019►, Golf 08 2020►, Tiguan, Arteon 4721
4 18 Removing and installing coolant pipe 4723
4 19 Removing and installing battery module assembly 4726
4 19 1 Removing and installing battery module assembly, Golf ►08 2020 4726
4 19 2 Removing and installing battery module assembly, Passat ►09 2019 4734
4 19 3 Removing and installing battery module assembly, Passat 09 2019► and Golf 08 2020►, Tiguan, Arteon 4740
4 20 Removing and installing battery module assembly wiring harness 4746
4 21 Removing and installing high voltage system connection 4747
4 21 1 Removing and installing high voltage system connection, Golf ►08 2020 4747
4 21 2 Removing and installing high voltage system connection, Passat, Golf 08 2020►, Tiguan, Arteon 4748
4 22 Removing and installing coolant temperature sender 1 for high-voltage battery -G898- and coolant temperature sender 2 for high-voltage battery -G899- 4750
4 23 Closing high-voltage battery 1 -AX2- 4751
4 23 1 Closing high-voltage battery 1 -AX2-, Golf ►08 2020 4751
4 23 2 Closing high-voltage battery 1 -AX2-, Passat ►09 2019 4757
4 23 3 Closing high-voltage battery 1 -AX2-, Passat 09 2019► ,Golf 08 2020►, Tiguan, Arteon 4757
4 24 Removing and installing battery modules -J1068-/-J991- 4759
4 24 1 Removing and installing battery modules -J1068-/-J991-, Golf ►08 2020 4759
4 24 2 Removing and installing battery modules -J1068-/-J991-, Passat, Golf 08 2020►, Tiguan, Arteon 4762
4 25 Removing and installing battery modules -J992-/-J993- 4768
4 25 1 Removing and installing battery modules -J992-/-J993-, Golf ►08 2020 4768
4 25 2 Removing and installing battery modules -J992-/-J993-, Passat, Golf 08 2020►, Tiguan, Arteon 4771
4 26 Removing and installing battery modules -J994-/-J995- 4776
4 26 1 Removing and installing battery modules -J994-/-J995-, Golf ►08 2020 4776
4 26 2 Removing and installing battery modules -J994-/-J995-, Passat, Golf 08 2020►, Tiguan, Arteon 4779
4 27 Removing and installing battery modules -J996-/-J997- 4785
4 27 1 Removing and installing battery modules -J996-/-J997-, Golf ►08 2020 4785
4 27 2 Removing and installing battery modules -J996-/-J997-, Passat, Golf 08 2020►, Tiguan, Arteon 4788
5 Power and control electronics for electric drive 4793
5 1 Assembly overview – power and control electronics for electric drive 4793
5 1 1 Assembly overview – power and control electronics for electric drive, Passat, Golf 03 2017►, Tiguan, Arteon 4793
5 1 2 Assembly overview – power and control electronics for electric drive, Golf ►03 2017 4795
5 2 Assembly overview – mounting for power and control electronics for electric drive 4797
5 2 1 Assembly overview – mounting for power and control electronics for electric drive, Passat, Golf 03 2017►, Tiguan, Arteon 4797
5 2 2 Assembly overview – mounting for power and control electronics for electric drive, Golf ►03 2017 4798
5 3 Removing and installing power and control electronics for electric drive 4800
5 3 1 Removing and installing power and control electronics for electric drive, Passat, Golf 03 2017►, Tiguan, Arteon 4800
5 3 2 Removing and installing power and control electronics for electric drive, ►Golf 03 2017 4807
5 4 Removing and installing base retainer for power and control electronics for electric drive -JX1- 4812
5 4 1 Removing and installing base retainer for power and control electronics for electric drive -JX1-, Passat, Golf 03 2017►, Tiguan, Arteon 4812
5 4 2 Removing and installing base retainer for power and control electronics for electric drive -JX1-, ►Golf 03 2017 4814
5 5 Removing and installing high-voltage system fuse 3 -S353- 4815
5 5 1 Removing and installing high-voltage system fuse 3 -S353-, Passat, Golf 03 2017►, Tiguan, Arteon 4815
5 5 2 Removing and installing high-voltage system fuse 3 -S353-, ►Golf 03 2017 4818
6 Charging unit for high-voltage battery 4821
6 1 Assembly overview – charging unit for high-voltage battery 4821
6 2 Removing and installing charging unit 1 for high-voltage battery -AX4- 4823
6 2 1 Removing and installing charging unit 1 for high-voltage battery -AX4-, Passat, Golf 08 2020►, Tiguan, Arteon 4823
6 2 2 Removing and installing charging unit 1 for high-voltage battery -AX4-, Golf, ►Golf 08 2020 4826
6 3 Removing and installing bracket for charging unit 1 for high-voltage battery -AX4- 4829
6 3 1 Removing and installing bracket for charging unit 1 for high-voltage battery -AX4-, Passat, Golf 08 2020►, Tiguan, Arteon 4829
6 3 2 Removing and installing bracket for charging unit 1 for high-voltage battery -AX4-, Golf ►08 2020 4830
7 Electric drive motor 4832
7 1 Removing and installing three-phase current drive -VX54- 4832
7 2 Removing and installing drive motor temperature sender -G712- 4832
7 3 Removing and installing drive motor rotor position sender 1 -G713- 4832
8 High-voltage cables 4833
8 1 Overview of fitting locations – high-voltage cables 4833
8 1 1 Overview of fitting locations – high-voltage cables, charging unit, Passat, Golf ►08 2020, Arteon 4833
8 1 2 Overview of fitting locations – high-voltage cables, charging unit, Golf 08 2020►, Tiguan 4834
8 1 3 Overview of fitting locations – high-voltage cables, power and control electronics for electric drive, high-voltage battery 4835
8 1 4 Overview of fitting locations – high-voltage cables, power and control electronics for electric drive, electric drive motor 4836
8 2 Removing and installing high-voltage wiring harness for high-voltage battery 4837
8 2 1 Removing and installing high-voltage wiring harness for high-voltage battery, Passat, Golf 08 2020►, Tiguan, Arteon 4837
8 2 2 Removing and installing high-voltage wiring harness for high-voltage battery, Golf 4843
8 3 Removing and installing high-voltage wiring harness for drive motor 4848
8 3 1 Removing and installing high-voltage wiring harness for drive motor, Passat, Golf 08 2020►, Tiguan, Arteon 4848
8 3 2 Removing and installing high-voltage wiring harness for drive motor, Golf ►08 2020 4852
8 4 Removing and installing high-voltage cable for power and control electronics for electric drive 4855
8 5 Removing and installing high-voltage cable for high-voltage heater (PTC) 4857
8 6 Removing and installing high-voltage cable for electrical air conditioner compressor 4859
9 Charging socket 4862
9 1 Assembly overview – charging socket 4862
9 1 1 Assembly overview – charging socket, Passat, Arteon 4862
9 1 2 Assembly overview – charging socket, Golf ►08 2020 4863
9 1 3 Assembly overview – charging socket, Golf 08 2020► 4864
9 1 4 Assembly overview – charging socket, Tiguan 4865
9 2 Removing and installing high-voltage battery charging socket 1 -UX4- 4867
9 2 1 Removing and installing high-voltage battery charging socket 1 -UX4-, Passat, Arteon 4867
9 2 2 Removing and installing high-voltage battery charging socket 1 -UX4-, Golf ►08 2020 4870
9 2 3 Removing and installing high-voltage battery charging socket 2 -UX5-, Golf 08 2020► 4873
9 2 4 Removing and installing high-voltage battery charging socket 2 -UX5-, Tiguan 4875
9 3 Manual release mechanism for charging socket 4877
9 3 1 Manual release mechanism for charging socket, Passat, Arteon 4877
9 3 2 Manual release mechanism for charging socket, Golf ►08 2020 4879
9 3 3 Manual release mechanism for charging socket, Golf 08 2020► 4880
9 3 4 Emergency release of charging socket, Tiguan 4881
9 4 Removing and installing module for battery charge selector buttons -EX32- 4883
9 4 1 Removing and installing module for battery charge selector buttons -EX32-, Passat, Arteon 4883
9 4 2 Removing and installing module for battery charge selector buttons -EX32-, Golf ►08 2020 4884
9 4 3 Removing and installing module for battery charge selector buttons -EX32-, Tiguan 4884
10 De-energising high-voltage system 4886
11 Re-energising high-voltage system 4888
12 Potential equalisation lines 4889
12 1 General notes – potential equalisation lines 4889
12 2 Overview of fitting locations – potential equalisation lines 4889
12 2 1 Overview of fitting locations – potential equalisation lines, part 1, Passat, Arteon 4889
12 2 2 Overview of fitting locations – potential equalisation lines, part 1, Golf ►08 2020 4890
12 2 3 Overview of fitting locations – potential equalisation lines, part 1, Golf 08 2020►, Tiguan 4891
12 2 4 Overview of fitting locations – potential equalisation lines, part 2 4892
12 3 Removing and installing potential equalisation line for high-voltage battery 1 -AX2- 4894
D4B8071B7F6 Electrical system 4895
00 – Technical data 4903
1 Safety information 4903
1 1 Safety measures when working on vehicles with start/stop system 4903
1 2 Safety precautions when using testers and measuring instruments during a road test 4903
2 Repair instructions 4904
2 1 Contact corrosion 4904
2 2 Routing and attachment of lines 4904
3 Battery 4905
3 1 Battery – general notes 4905
3 2 Types of battery 4905
27 – Starter, current supply, CCS 4906
1 Battery 4906
1 1 Assembly overview – battery 4906
1 1 1 Assembly overview – battery, battery in engine compartment 4906
1 1 2 Assembly overview – battery, battery in luggage compartment 4908
1 2 Removing and installing battery 4910
1 2 1 Removing and installing battery, battery in engine compartment 4910
1 2 2 Removing and installing battery, battery in luggage compartment 4913
1 3 Disconnecting and connecting battery 4917
1 3 1 Disconnecting and connecting battery, battery in engine compartment 4917
1 3 2 Disconnecting and connecting battery, battery in luggage compartment 4919
1 4 Removing and installing battery tray 4921
1 4 1 Removing and installing battery tray, battery in engine compartment 4921
1 4 2 Removing and installing battery tray, battery in luggage compartment 4922
1 5 Checking battery 4923
1 6 Charging battery 4923
1 7 Removing and installing earth wire with battery monitor control unit -J367- 4923
1 7 1 Removing and installing earth cable with battery monitor control unit -J367-, battery in engine compartment 4923
1 7 2 Removing and installing earth cable with battery monitor control unit -J367-, battery in luggage compartment 4924
1 8 Adapting battery monitor control unit -J367- 4926
2 Alternator 4927
2 1 Assembly overview – alternator 4927
2 1 1 Assembly overview – alternator without sliding bushes 4927
2 1 2 Assembly overview – alternator with sliding bushes 4927
2 2 Removing and installing alternator 4928
2 2 1 Removing and installing alternator, vehicles with TSI engine 4928
2 2 2 Removing and installing alternator, vehicles with TDI engine 4931
2 3 Checking alternator 4933
2 4 Removing and installing poly V-belt pulley 4934
2 4 1 Removing and installing poly V-belt pulley without freewheel 4934
2 4 2 Removing and installing poly V-belt pulley with freewheel, manufacturer: Bosch 4935
2 4 3 Removing and installing poly V-belt pulley with freewheel, manufacturer: Valeo 4937
2 4 4 Removing and installing decoupler pulley with freewheel 4940
2 5 Removing and installing voltage regulator 4943
2 5 1 Removing and installing voltage regulator, manufacturer: Bosch 4943
2 5 2 Removing and installing voltage regulator, manufacturer: Valeo 4945
3 Starter 4947
3 1 Assembly overview – starter 4947
3 1 1 Assembly overview – starter, vehicles with manual gearbox 4947
3 1 2 Assembly overview – starter, vehicles with dual clutch gearbox 4947
3 2 Removing and installing starter 4948
3 2 1 Removing and installing starter, vehicle with manual gearbox 4948
3 2 2 Removing and installing starter, vehicles with dual clutch gearbox 4951
4 Cruise control system (CCS) 4954
5 Start/stop system 4955
5 1 General description – start/stop system 4955
6 Adaptive cruise control 4956
6 1 Overview of fitting locations – adaptive cruise control 4956
6 2 Removing and installing automatic distance control unit 4956
6 3 Calibrating adaptive cruise control 4957
90 – Gauges, instruments 4958
1 Dash panel insert 4958
1 1 Assembly overview – dash panel insert 4958
1 1 1 Assembly overview – dash panel insert, dash panel insert with analogue instruments 4958
1 1 2 Assembly overview – dash panel insert, fully digital dash panel insert 4959
1 2 Assembly overview – head-up display 4960
1 3 Removing and installing dash panel insert -KX2- 4962
1 3 1 Removing and installing dash panel insert -KX2-, dash panel insert with analogue instruments 4962
1 3 2 Removing and installing dash panel insert -KX2-, fully digital dash panel insert 4964
1 4 Removing and installing control unit for head-up display 4967
2 Clock 4969
2 1 Removing and installing clock 4969
3 Horn 4970
3 1 Assembly overview – horn 4970
3 2 Removing and installing treble horn -H2- and bass horn -H7- 4970
92 – Windscreen wash/wipe system 4973
1 Windscreen wiper system 4973
1 1 Assembly overview – windscreen wiper system 4973
1 2 Moving wipers to service position 4975
1 3 Removing and installing wiper blade 4975
1 4 Removing and installing wiper arms 4977
1 5 Adjusting wiper arms 4978
1 6 Removing and installing wiper motor -V- 4980
1 7 Deactivating APP function of wiper motor 4981
1 8 Removing and installing rain and light sensor 4982
1 9 Repairing rain and light sensor 4985
1 9 1 Repairing rain and light sensor, TRW 4985
1 9 2 Repairing rain and light sensor, Valeo 4986
2 Windscreen washer system 4989
2 1 Assembly overview – windscreen washer system 4989
2 1 1 Assembly overview – windscreen washer system, washer fluid reservoir in front left wheel housing 4989
2 1 2 Assembly overview – windscreen washer system, washer fluid reservoir in front right wheel housing 4990
2 2 Removing and installing washer fluid reservoir 4992
2 2 1 Removing and installing washer fluid reservoir, washer fluid reservoir in front left wheel housing 4992
2 2 2 Removing and installing washer fluid reservoir, washer fluid reservoir in front right wheel housing 4994
2 3 Removing and installing windscreen washer fluid level sender 4996
2 3 1 Removing and installing windscreen washer fluid level sender, washer fluid reservoir in front left wheel housing 4996
2 3 2 Removing and installing windscreen washer fluid level sender, washer fluid reservoir in front right wheel housing 4997
2 4 Removing and installing windscreen washer pump 4998
2 4 1 Removing and installing washer pump, washer fluid reservoir in front left wheel housing 4998
2 4 2 Removing and installing washer pump, washer fluid reservoir in front right wheel housing 4998
2 5 Removing and installing spray jets 4999
2 6 Adjusting spray jets 5000
3 Headlight washer system 5002
3 1 Assembly overview – headlight washer system 5002
3 1 1 Assembly overview – headlight washer system, washer fluid reservoir in front left wheel housing 5002
3 1 2 Assembly overview – headlight washer system, washer fluid reservoir in front right wheel housing 5003
3 2 Removing and installing washer fluid reservoir 5003
3 3 Removing and installing headlight washer system pump -V11- 5004
3 3 1 Removing and installing headlight washer system pump -V11-, washer fluid reservoir in front left wheel housing 5004
3 3 2 Removing and installing headlight washer system pump -V11-, washer fluid reservoir in front right wheel housing 5004
3 4 Adjusting spray jets 5005
3 5 Removing and installing pop-up cylinder 5005
3 6 Renewing guide frame for headlight washer system 5007
4 Washer fluid lines 5009
4 1 Repairing washer fluid lines 5009
94 – Lights, bulbs, switches – exterior 5010
1 Headlights 5010
1 1 Assembly overview – headlight 5010
1 1 1 Assembly overview – LED headlights without variable light distribution 5010
1 1 2 Assembly overview – LED headlights with variable light distribution 5012
1 1 3 Assembly overview – add-on parts for headlights 5014
1 1 4 Assembly overview – repair kit for headlight housing 5015
1 2 Removing and installing headlight 5016
1 3 Adjusting headlights 5017
1 4 Adjusting headlight installation position 5017
1 5 Removing and installing front turn signal bulb -M5-/-M7- 5019
1 5 1 Removing and installing front turn signal bulb -M5-/-M7-, LED headlights without variable light distribution 5019
1 5 2 Removing and installing front turn signal bulb -M5-/-M7-, LED headlights with variable light distribution 5021
1 6 Installing repair kit for headlight housing 5022
1 7 Converting headlights from driving on right to driving on left 5024
1 8 Converting headlights from driving on left to driving on right 5024
1 9 Removing and installing headlight range control motor -V48-/-V49- 5024
1 10 Removing and installing headlight dipped beam bulb 5026
1 11 Removing and installing headlight main beam bulb -M30-/-M32- 5026
1 12 Removing and installing LED modules for daytime running light and side light -L176-/-L177- 5026
1 13 Removing and installing output module 1 for LED headlights -A27-/-A31- 5028
1 14 Removing and installing trim cover for LED headlight 5030
1 15 Removing and installing retaining frame for LED headlight 5031
1 16 Removing and installing trim strip for LED headlight 5033
1 17 Removing and installing dynamic cornering light control motor -V318-/-V319- 5033
1 18 Removing and installing bulbs for cornering light -L148-/-L149- 5034
1 19 Removing and installing output module for headlight -J667-/-J668- 5035
2 Lights in exterior mirror 5037
2 1 Assembly overview – lights in exterior mirror 5037
2 2 Removing and installing turn signal 5039
2 3 Removing and installing entry light in exterior mirror 5041
3 Tail light cluster 5042
3 1 Assembly overview – tail light cluster in body 5042
3 2 Assembly overview – tail light clusters in rear lid 5042
3 3 Removing and installing tail light in rear lid 5043
3 4 Adjusting installation position of tail light 5044
3 5 Removing and installing tail light cluster 5045
3 6 Removing and installing tail light bulb -M2-/-M4- 5046
3 7 Removing and installing rear fog light bulb -L46-/-L47- 5047
3 8 Removing and installing brake and tail light bulb -M21-/-M22- 5047
3 9 Removing and installing reversing light bulb 5047
3 10 Removing and installing turn signal bulb 5047
4 High-level brake light 5048
4 1 Assembly overview – high-level brake light 5048
4 2 Removing and installing high-level brake light 5049
5 Number plate light 5052
5 1 Removing and installing number plate light -X4-/-X5- 5052
5 2 Removing and installing bulb for number plate light -X4-/-X5- 5053
6 Entry and start authorisation system 5054
6 1 Overview of fitting locations – entry and start authorisation system 5054
6 1 1 Overview of fitting locations – entry and start authorisation system, left-hand drive vehicles 5054
6 1 2 Overview of fitting locations – entry and start authorisation system, right-hand drive vehicles 5055
6 2 Overview of fitting locations – keyless entry system 5056
6 3 Removing and installing entry and start authorisation control unit -J518- 5058
6 4 Removing and installing door exterior handle contact sensor -G415-/-G416- 5059
6 5 Removing and installing contact sensor for rear exterior door handle -G417-/-G418- 5060
6 6 Removing and installing interior aerial 1 for entry and start system -R138- 5060
6 7 Removing and installing interior aerial 2 for entry and start system -R139- 5061
6 8 Removing and installing driver side aerial for entry and start system -R134- 5061
6 9 Removing and installing front passenger side aerial for entry and start system -R135- 5062
6 10 Removing and installing rear entry and start authorisation aerial -R165-/-R166- 5062
6 11 Removing and installing luggage compartment aerial for entry and start system -R137- 5062
6 12 Removing and installing rear bumper aerial for entry and start system -R136- 5063
6 13 Removing and installing rear lid power opening control unit -J938- 5063
6 14 Removing and installing rear lid power opening sender -G750-/-G760- 5064
7 Steering column switch module 5066
7 1 Assembly overview – steering column switch module 5066
7 2 Removing and installing steering column switch module 5067
7 3 Removing and installing steering column electronics control unit -J527- 5070
7 4 Removing and installing base for steering column combination switch 5073
7 5 Removing and installing turn signal switch -E2- 5074
7 6 Removing and installing cruise control system switch -E45- 5076
7 7 Removing and installing intermittent wiper switch -E22- 5076
7 8 Removing and installing immobiliser reader coil -D2- 5076
8 Parking aid 5078
8 1 Assembly overview – parking aid 5078
8 1 1 Assembly overview – parking aid, left-hand drive vehicles 5078
8 1 2 Assembly overview – parking aid, right-hand drive vehicles 5079
8 2 Removing and installing parking aid control unit -J446- 5081
8 2 1 Removing and installing parking aid control unit -J446-, left-hand drive vehicle 5081
8 2 2 Removing and installing parking aid control unit -J446-, RHD vehicle 5081
8 3 Removing and installing front parking aid warning buzzer -H22- 5082
8 3 1 Removing and installing front parking aid warning buzzer -H22-, left-hand drive vehicles 5082
8 3 2 Removing and installing front parking aid warning buzzer -H22-, right-hand drive vehicles 5083
8 4 Removing and installing rear parking aid warning buzzer -H15- 5084
8 5 Removing and installing front parking aid senders 5084
8 6 Removing and installing rear parking aid senders 5085
9 Park assist steering 5087
9 1 Assembly overview – park assist steering 5087
9 1 1 Assembly overview – park assist steering, left-hand drive vehicles 5087
9 1 2 Assembly overview – park assist steering, right-hand drive vehicles 5087
9 2 Removing and installing park assist steering control unit -J791- 5088
9 3 Removing and installing front senders 5088
9 4 Removing and installing rear senders 5089
10 Automatic headlight range control 5091
10 1 Assembly overview – automatic headlight range control 5091
10 1 1 Assembly overview – automatic headlight range control, left-hand drive vehicles 5091
10 1 2 Assembly overview – automatic headlight range control, right-hand drive vehicles 5091
10 2 Removing and installing cornering light and headlight range control unit -J745- 5092
10 2 1 Removing and installing control unit for cornering light and headlight range control -J745-, left-hand drive vehicles 5092
10 2 2 Removing and installing control unit for cornering light and headlight range control -J745-, right-hand drive vehicles 5093
11 Towing bracket 5095
11 1 Assembly overview – towing bracket socket 5095
11 2 Trailer socket -U10- 5095
11 3 Removing and installing trailer detector control unit -J345- 5096
96 – Lights, bulbs, switches – interior 5098
1 Lights 5099
1 1 Overview of fitting locations – lights in dash panel 5100
1 2 Overview of fitting locations – lights in front doors 5100
1 3 Overview of fitting locations – lights in rear doors 5101
1 4 Overview of fitting locations – lights in centre console 5102
1 5 Overview of fitting locations – lights in luggage compartment 5103
1 6 Overview of fitting locations – lights in roof trim 5104
1 7 Removing and installing glove compartment light -W6- 5105
1 8 Replacing bulb for glove compartment light -W6- 5106
1 9 Removing and installing front footwell light -K268-/-K269- 5106
1 9 1 Removing and installing front footwell light -K268-, driver side 5106
1 9 2 Removing and installing front footwell light -K269-, front passenger side 5107
1 10 Removing and installing front footwell illumination bulb -L151-/-L152- 5108
1 11 Removing and installing Central locking SAFELOCK function warning lamp -K133- 5108
1 12 Removing and installing interior door handle illumination bulb -L146-/-L147- 5108
1 13 Removing and installing reflectors in door 5109
1 14 Removing and installing front entry light -W31-/-W32- 5110
1 15 Removing and installing door warning lamp -W30-/-W36- 5111
1 16 Removing and installing rear interior door handle illumination bulb -L221-/-L222- 5112
1 17 Removing and installing light for front door ambient lighting -W86-/-W87- 5112
1 18 Removing and installing light 1 for rear door ambient lighting -L201-/-L202- 5113
1 19 Removing and installing light 2 for front door ambient lighting -W97-/-W98- 5113
1 20 Removing and installing bulb for background lighting in rear door -L166-/-L167- 5114
1 21 Removing and installing lights for dashboard background lighting -L229-/-L230- 5114
1 22 Removing and installing selector lever position display -Y26- 5114
1 23 Removing and installing luggage compartment light -W3-/-W115- 5115
1 24 Removing and installing illuminated vanity mirror -W20-/-W14- 5115
1 25 Removing and installing bulb for front interior light -W1- 5116
1 25 1 Removing and installing bulb for front interior light -W1- with incandescent bulbs 5116
1 25 2 Removing and installing light for front interior light -W1- with LED 5118
1 26 Removing and installing bulb for rear interior light -W43- 5119
1 26 1 Removing and installing bulb for rear interior light -W43- with incandescent bulbs 5119
1 26 2 Removing and installing light for rear interior light -W43- with LED 5120
1 27 Removing and installing bulb for front reading light -W13-/-W19- 5121
1 28 Removing and installing bulb for rear reading light -W11-/-W12- 5121
2 Controls 5123
2 1 Overview of fitting locations – controls in dash panel 5124
2 2 Overview of fitting locations – controls in front doors 5126
2 3 Overview of fitting locations – controls in rear doors 5126
2 4 Overview of fitting locations – controls in centre console 5127
2 5 Overview of fitting locations – controls in luggage compartment 5128
2 6 Overview of fitting locations – controls in roof trim 5129
2 6 1 Overview of fitting locations – controls in roof trim, except for panel light 5129
2 6 2 Overview of fitting locations – controls in roof trim, panel light only 5131
2 7 Removing and installing rotary light switch -EX1- 5133
2 8 Removing and installing switch for head-up display -E736- 5134
2 9 Removing and installing steering wheel heater button -E522- 5134
2 10 Removing and installing driving mode selection button -E735- 5134
2 11 Removing and installing Start/Stop operation button -E693- 5134
2 12 Removing and installing TCS and ESP button -E256- 5135
2 13 Removing and installing parking aid button -E266- 5135
2 14 Removing and installing park assist steering button -E581- 5135
2 15 Removing and installing centre switch module in dash panel -EX22- 5135
2 16 Removing and installing switch module in centre console -EX23-/-EX30- 5136
2 17 Removing and installing hazard warning light switch -EX3- 5138
2 18 Removing and installing buttons for seat heating -E653-/-E654- 5138
2 19 Removing and installing glove compartment light switch -E26- 5138
2 20 Removing and installing exterior mirror adjuster -EX11- 5139
2 21 Removing and installing operating unit for window regulator in driver door -E512- 5140
2 22 Removing and installing front passenger side window regulator button -E716- 5141
2 23 Removing and installing driver side interior locking button for central locking system -E308- 5141
2 24 Removing and installing rear lid remote release button -E233- 5142
2 25 Removing and installing button for deactivating interior monitoring and vehicle inclination sensor -E616- 5143
2 26 Removing and installing door contact switch -F2-/-F3- 5144
2 27 Removing and installing rear window regulator button -E711-/-E713- 5144
2 28 Removing and installing rear door contact switches -F10-/-F11- 5145
2 29 Removing and installing electromechanical parking brake button -E538-/auto-hold button -E540- 5145
2 30 Removing and installing the starter button -E378- 5146
2 31 Removing and installing electric hinged tow coupling attachment button -E474- 5147
2 32 Removing and installing button to close rear lid in luggage compartment -E406- 5148
2 33 Removing and installing rear lid warning buzzer -H32- 5149
2 34 Removing and installing rear lid contact switch 5150
2 35 Removing and installing vanity mirror contact switch -F147-/-F148- 5150
2 36 Removing and installing sunroof button -E325- 5150
2 37 Removing and installing front interior light/reading light 5151
2 37 1 Removing and installing front interior light/reading light, except for panel light 5151
2 37 2 Removing and installing front interior light/reading light, panel light only 5152
2 38 Removing and installing rear interior light/reading light 5154
2 39 Removing and installing front reading light button -E633-/-E634- 5155
3 Anti-theft alarm 5157
3 1 Assembly overview – interior monitor 5157
3 2 Assembly overview – alarm horn 5157
3 2 1 Assembly overview – alarm horn 5157
3 2 2 Assembly overview – alarm horn NAR 5158
3 3 Removing and installing alarm horn -H12- 5159
3 4 Removing and installing alarm horn -H12- 5159
3 5 Removing and installing alarm horn -H12- NAR 5160
3 6 Removing and installing anti-theft alarm sensor -G578- 5161
4 Lane change assist 5163
4 1 Assembly overview – lane change assist 5163
4 2 Removing and installing lane change assist warning lamp in exterior mirror -K233-/-K234- 5165
4 3 Removing and installing lane change assist control unit -J769-/-J770- 5165
4 4 Calibrating lane change assist 5167
4 4 1 Measurement location 5167
4 4 2 Preparatory measures for calibration 5169
4 4 3 Calibrating lane change assist control unit -J769-/-J770- 5173
5 Front camera for driver assist systems 5176
5 1 Removing and installing front camera for driver assist systems 5176
6 Cigarette lighter, socket 5177
6 1 Assembly overview – DC/AC converter with socket, 12 V-230 V 5177
6 2 Removing and installing cigarette lighter -U1- 5178
6 3 Removing and installing socket illumination bulb -L42- 5178
6 4 Removing and installing rear cigarette lighter illumination bulb -L32- 5178
6 5 Removing and installing electric socket -U- 5178
6 6 Removing and installing DC/AC converter with socket, 12 V-230 V -U13- 5178
97 – Wiring 5180
1 Relay carriers, fuse holders, electronics boxes 5180
1 1 Overview of fitting locations – relay carriers, fuse holders, electronics boxes 5180
1 1 1 Relay carriers, fuse carriers, electronics box (engine compartment) 5180
1 1 2 Relay carrier, fuse carrier in dash panel/A-pillar, LHD vehicles 5182
1 1 3 Relay carrier, fuse carrier in dash panel/A-pillar, RHD vehicles 5182
1 1 4 Main fuse box on battery, luggage compartment, left 5183
1 2 Removing and installing electronics box 5184
1 3 Removing and installing relay and fuse holder in electronics box 5187
1 3 1 Removing and installing fuse holder B -SB- 5187
1 3 2 Removing and installing fuse holder A -SA- 5189
1 4 Removing and installing relay and fuse carrier behind dash panel 5189
1 4 1 Removing and installing relay and fuse carrier behind dash panel, LHD vehicles 5189
1 4 2 Removing and installing relay and fuse carrier behind dash panel, RHD vehicles 5190
1 5 Removing and installing main fuse carrier 5192
2 Control units 5194
2 1 Overview of fitting locations – control units 5194
2 1 1 Overview of fitting locations – control units, left-hand drive vehicles 5194
2 1 2 Overview of fitting locations – control units, right-hand drive vehicles 5195
2 2 Removing and installing onboard supply control unit -J519- 5195
2 2 1 Removing and installing onboard supply control unit -J519-, left-hand drive vehicles 5195
2 2 2 Removing and installing onboard supply control unit -J519-, right-hand drive vehicles 5197
2 3 Removing and installing data bus diagnostic interface -J533- 5200
2 4 Removing and installing bracket for onboard supply control unit -J519- 5201
2 4 1 Removing and installing bracket for onboard supply control unit -J519-, LHD vehicles 5201
2 4 2 Removing and installing bracket for onboard supply control unit -J519-, right-hand drive vehicle 5202
2 5 Renewing bracket for onboard supply control unit -J519- 5203
2 5 1 Renewing bracket for onboard supply control unit -J519-, LHD vehicles 5203
2 5 2 Renewing bracket for onboard supply control unit -J519-, RHD vehicles 5204
2 6 Removing and installing parking aid control unit -J446-/park assist steering control unit -J791- 5204
3 Connectors 5205
3 1 Repairing electrical wiring harnesses and plug-in connections 5205
3 1 1 Repairs to wiring harnesses and connectors 5205
3 1 2 Repairing connector housings and electrical connectors 5205
4 Releasing and dismantling connector housings 5206
5 Repairing aerial wires 5207
6 Fibre optic cables 5208
7 Vehicle diagnosis, testing and information systems 5209
D4B8071B7F9 4 cylinder direct injection engine (1 5 l engine 4V EA 211 turbocharger) 5210
00 – Technical data 5216
1 Safety information 5216
1 1 Safety regulations for working on fuel supply 5216
1 2 Safety measures when working on vehicles with a start/stop system 5216
1 3 Safety precautions when using testers and measuring instruments during a road test 5217
1 4 Safety precautions when working on the cooling system 5217
1 5 Safety precautions when working on ignition system 5217
2 Identification 5218
2 1 Engine number/engine data 5218
3 Repair instructions 5222
3 1 Rules for cleanliness 5222
3 2 General information 5222
3 3 General repair instructions 5223
3 4 Foreign objects in engine 5223
3 5 Contact corrosion 5223
3 6 Routing and attachment of lines 5223
3 7 Fitting radiator and condensers 5223
3 8 Checking vacuum system 5223
10 – Removing and installing engine 5225
1 Removing and installing engine 5225
1 1 Removing engine 5225
1 2 Separating engine and gearbox 5235
1 3 Securing engine on engine and gearbox support 5238
1 4 Installing engine 5239
2 Assembly mountings 5244
2 1 Assembly overview – assembly mountings 5244
2 1 1 Assembly overview – assembly mountings (without belt-driven starter-alternator) 5244
2 1 2 Assembly overview – assembly mountings (without belt-driven starter-alternator) 5247
2 1 3 Assembly overview – assembly mountings (without belt-driven starter-alternator) 5250
2 1 4 Assembly overview – assembly mountings (with belt-driven starter-alternator) 5253
2 2 Removing and installing engine mounting 5256
2 3 Removing and installing gearbox mounting 5257
2 4 Removing and installing pendulum support 5259
2 5 Supporting engine in installation position 5260
2 5 1 Supporting engine in installation position, Golf, Golf Estate and Golf SV 5260
2 5 2 Supporting engine in installation position, Arteon, Passat, Passat Estate, Arteon Shooting Brake 5267
2 5 3 Supporting engine in installation position, T-Roc and T-Roc Cabriolet 5273
2 5 4 Supporting engine in installation position, Touran and Tiguan 5280
2 5 5 Supporting engine in installation position, Polo 5285
2 5 6 Supporting engine in installation position, T-Cross 5289
2 6 Adjusting assembly mountings 5293
2 7 Checking adjustment of assembly mountings 5295
3 Engine cover panel 5297
3 1 Removing and installing engine cover 5297
13 – Crankshaft group 5298
1 Cylinder block (pulley end) 5298
1 1 Assembly overview – poly V-belt drive 5298
1 1 1 Assembly overview – poly V-belt drive, vehicles without air conditioner compressor 5298
1 1 2 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor 5300
1 1 3 Assembly overview – poly V-belt drive, vehicles with air conditioner compressor and starter-alternator 5302
1 2 Removing and installing poly-V belt 5304
1 2 1 Removing and installing poly V-belt, vehicles without air conditioner compressor 5304
1 2 2 Removing and installing poly V-belt, vehicles with air conditioner compressor 5306
1 2 3 Removing and installing poly V-belt, vehicles with air conditioner compressor and starter-alternator 5308
1 3 Removing and installing tensioner for poly V-belt 5309
1 3 1 Removing and installing tensioner for poly V-belt, vehicles without air conditioner compressor 5309
1 3 2 Removing and installing tensioner for poly V-belt, vehicles with air conditioner compressor 5310
1 3 3 Removing and installing poly V-belt tensioner, vehicles with air conditioner compressor and starter-alternator 5311
1 4 Removing and installing vibration damper 5311
1 5 Removing and installing engine support 5314
1 6 Renewing crankshaft oil seal – belt pulley end 5316
2 Cylinder block, gearbox end 5320
2 1 Assembly overview – cylinder block, gearbox end 5320
2 2 Removing and installing flywheel 5323
2 2 1 Removing and installing flywheel 5323
2 2 2 Preloading teeth in flywheel – vehicles with dual clutch gearbox 5325
2 3 Removing and installing sealing flange on gearbox side 5325
3 Crankshaft 5338
3 1 Renewing needle bearing in crankshaft 5338
3 2 Crankshaft dimensions 5340
3 3 Measuring axial clearance of crankshaft 5340
4 Pistons and conrods 5342
4 1 Assembly overview – pistons and conrods 5342
4 2 Removing and installing pistons 5344
4 3 Checking pistons and cylinder bores 5346
4 4 Separating new conrod 5348
4 5 Checking radial clearance of conrods 5348
4 6 Removing and installing oil spray jets 5349
4 7 Setting piston to TDC position 5350
15 – Cylinder head, valve gear 5353
1 Cylinder head 5353
1 1 Assembly overview – cylinder head 5353
1 2 Assembly overview – camshaft housing 5355
1 3 Removing and installing cylinder head 5358
1 4 Removing and installing camshaft housing 5362
1 5 Checking compression 5368
2 Toothed belt drive 5371
2 1 Assembly overview – toothed belt cover 5371
2 2 Assembly overview – toothed belt 5372
2 3 Assembly overview – valve timing tool 5375
2 4 Removing and installing toothed belt guard 5375
2 4 1 Removing and installing upper toothed belt guard 5375
2 4 2 Removing and installing lower toothed belt guard 5376
2 5 Removing and installing toothed belt 5376
2 6 Preassembling and installing valve timing tool 5383
2 6 1 Preassembling valve timing tool 5383
2 6 2 Installing test tool -VAS 611 007- 5386
2 6 3 Teaching in test tool -VAS 611 007- electronically and performing basic setting 5390
2 7 Checking valve timing 5393
2 8 Adjusting valve timing 5396
2 9 Removing toothed belt from camshaft 5407
3 Valve gear 5412
3 1 Assembly overview – valve gear 5412
3 2 Removing and installing camshaft oil seal 5415
3 2 1 Removing and installing camshaft oil seal for holder of inlet camshaft control valve 1 -N727- 5415
3 2 2 Removing and installing camshaft oil seal for inlet camshaft, belt pulley end 5418
3 2 3 Removing and installing exhaust camshaft oil seal, pulley end 5422
3 2 4 Removing and installing exhaust camshaft oil seal, gearbox end 5424
3 3 Removing and installing camshaft adjuster 5427
3 3 1 Removing and installing camshaft adjuster, inlet side 5427
3 3 2 Removing and installing camshaft adjuster, exhaust side 5433
3 4 Removing and installing cam actuators 5439
3 5 Removing and installing inlet camshaft control valve 1 -N727- 5441
3 6 Removing and installing exhaust camshaft control valve 1 -N318- 5442
3 7 Removing and installing valve stem seals 5443
3 7 1 Removing and installing valve stem seals (cylinder head installed) 5443
3 7 2 Removing and installing valve stem seals (cylinder head removed) 5451
3 8 Removing and installing holder for oil seal 5458
4 Inlet and exhaust valves 5462
4 1 Checking valve guides 5462
4 2 Checking valves 5463
4 3 Valve dimensions 5463
17 – Lubrication 5464
1 Sump, oil pump 5464
1 1 Assembly overview – sump/oil pump 5464
1 2 Engine oil: 5469
1 3 Removing and installing sump 5469
1 4 Removing and installing oil pump 5474
1 5 Removing and installing oil level and oil temperature sender -G266- 5477
2 Engine oil cooler 5478
2 1 Assembly overview – engine oil cooler 5478
2 2 Removing and installing engine oil cooler 5478
3 Crankcase ventilation 5480
3 1 Assembly overview – crankcase breather system 5480
3 2 Removing and installing oil separator 5482
3 2 1 Removing and installing lower oil separator 5482
3 2 2 Removing and installing upper oil separator 5484
4 Oil filter, oil pressure switch 5486
4 1 Assembly overview – oil pressure switches/oil pressure control 5486
4 2 Removing and installing oil pressure sender -G10- 5486
4 3 Checking oil pressure and oil pressure switch 5488
4 4 Removing and installing oil filter housing 5488
4 5 Removing and installing oil pressure regulating valve -N428- 5489
19 – Cooling 5491
1 Cooling system/coolant 5491
1 1 Connection diagram – coolant hoses 5491
1 2 Checking cooling system for leaks 5493
1 3 Draining and adding coolant 5497
1 4 Flushing cooling system 5505
2 Coolant pump, regulation of cooling system 5520
2 1 Assembly overview – coolant pump, thermostat 5520
2 2 Assembly overview – electric coolant pump 5522
2 3 Assembly overview – coolant temperature sender 5522
2 4 Removing and installing electric coolant pump 5523
2 5 Removing and installing coolant pump 5526
2 6 Removing and installing toothed belt pulley for coolant pump 5531
2 7 Removing and installing coolant temperature sender -G62- 5535
2 8 Removing and installing radiator outlet coolant temperature sender -G83- 5537
2 9 Removing and installing engine outlet coolant temperature sender -G82- 5539
2 10 Removing and installing engine temperature regulation module -GX33- 5541
2 11 Checking coolant pump 5545
3 Coolant pipes 5551
3 1 Assembly overview – coolant pipes 5551
3 2 Removing and installing coolant pipes 5553
3 2 1 Removing and installing lower left coolant pipe 5553
3 2 2 Removing and installing upper left coolant pipe 5555
3 2 3 Removing and installing upper front coolant pipe 5558
3 2 4 Removing and installing lower front coolant pipe 5560
4 Radiator, radiator fan 5562
4 1 Assembly overview – radiator/radiator fan 5562
4 2 Assembly overview – radiator cowl and radiator fan 5564
4 2 1 Assembly overview – radiator cowl with one radiator fan 5564
4 2 2 Assembly overview – radiator cowl with 2 radiator fans 5565
4 3 Assembly overview – radiator blind 5566
4 3 1 Assembly overview – radiator blind 5566
4 3 2 Assembly overview – components of radiator blind 5568
4 4 Removing and installing radiator 5569
4 5 Removing and installing water radiator for charge air cooling circuit 5572
4 6 Removing and installing radiator cowl 5577
4 7 Removing and installing radiator fan 5578
4 7 1 Removing and installing radiator fan, vehicles with one radiator fan 5578
4 7 2 Removing and installing radiator fan, vehicles with two radiator fans 5579
4 8 Removing and installing radiator blind 5580
4 9 Removing and installing radiator blind control motor -V544- 5582
21 – Turbocharging/supercharging 5588
1 Turbocharger 5588
1 1 Assembly overview – turbocharger 5588
1 1 1 Assembly overview – turbocharger, wastegate turbocharger 5588
1 1 2 Assembly overview – turbocharger (variable turbocharger geometry) 5590
1 1 3 Assembly overview – lines on turbocharger 5592
1 2 Removing and installing turbocharger 5594
1 3 Removing and installing connection for turbocharger 5599
1 4 Removing and installing charge pressure control module -GX34- 5601
1 4 1 Removing and installing charge pressure control module -GX34-, wastegate turbocharger 5601
1 4 2 Removing and installing charge pressure control module -GX34-, variable turbocharger geometry 5604
2 Charge air system 5606
2 1 Assembly overview – charge air system 5606
2 2 Removing and installing charge air cooler 5609
2 3 Removing and installing charge pressure sender -GX26- 5612
2 4 Checking charge air system for leaks 5613
2 5 Removing and installing air pipe 5617
2 5 1 Removing and installing air intake pipe between charge air cooler and turbocharger 5617
2 5 2 Removing and installing air intake pipe between charge air cooler and intake manifold 5620
2 6 Checking charge air cooler for leaks 5624
24 – Mixture preparation – injection 5630
1 Injection system 5630
1 1 Overview of fitting locations – injection system 5630
2 Air filter 5640
2 1 Assembly overview – air filter housing 5640
2 2 Removing and installing air filter housing 5642
2 3 Removing and installing air guide on lock carrier 5644
2 3 1 Removing and installing air guide on lock carrier, Golf, Golf Estate, Golf SV, Tiguan, Touran; Arteon, Passat, Passat Estate, Arteon Shooting Brake 5644
2 3 2 Removing air duct on lock carrier, T-Roc and T-Roc Cabriolet 5646
2 3 3 Removing and installing air guide on lock carrier, Polo and T-Cross 5647
3 Intake manifold 5648
3 1 Assembly overview – intake manifold 5648
3 2 Removing and installing intake manifold 5651
3 3 Removing and installing throttle valve module -GX3- 5657
3 4 Cleaning throttle valve module -GX3- 5659
4 Injectors 5661
4 1 Assembly overview – fuel rail with injectors 5661
4 2 Removing and installing fuel rail 5663
4 3 Removing and installing injectors 5664
4 4 Cleaning injectors 5672
5 Senders and sensors 5674
5 1 Removing and installing intake manifold sender -GX9- 5674
5 2 Removing and installing fuel pressure sender -G247- 5675
5 3 Checking fuel pressure sender -G247- 5677
5 3 1 Checking fuel pressure sender -G247-, using pressure sensor tester -VAS 6394- and vehicle diagnostic tester 5677
5 3 2 Checking fuel pressure sender -G247-, using vehicle diagnostic tester 5679
5 4 Removing and installing exhaust gas pressure sensor 1 -G450- 5681
5 5 Removing and installing air mass measurement module -GX35- 5682
6 High-pressure pump 5684
6 1 Assembly overview – high-pressure pump 5684
6 2 Removing and installing high-pressure pump 5685
6 3 Removing and installing high-pressure pipe 5687
7 Lambda probe 5689
7 1 Assembly overview – Lambda probe 5689
7 2 Removing and installing Lambda probe 5690
8 Engine control unit 5692
8 1 Removing and installing engine control unit -J623- 5692
8 1 1 Removing and installing engine control unit -J623- 5692
8 1 2 Removing and installing engine control unit -J623- (with metal locking plate) 5693
8 1 3 Removing and installing engine control unit -J623- (with protective housing) 5696
26 – Exhaust system 5700
1 Exhaust pipes and silencers 5700
1 1 Assembly overview – silencers 5700
1 1 1 –Assembly overview – silencers, Golf, Golf Estate, Golf SV and T-Roc Cabriolet 5700
1 1 2 Assembly overview – silencer, Arteon, Passat; Passat Estate, Arteon Shooting Brake 5702
1 1 3 Assembly overview – silencers, T-Roc with all-wheel drive 5704
1 1 4 Assembly overview – silencers, T-Roc with front-wheel drive 5706
1 1 5 Assembly overview – silencers, Touran 5708
1 1 6 Assembly overview – silencers, Tiguan 5710
1 1 7 Assembly overview – silencers, Polo, T-Cross 5712
1 1 8 Assembly overview silencers, Golf Estate 5714
1 2 Removing and installing silencer 5716
1 2 1 Removing and installing silencer, Golf, Golf Estate, Golf SV and T-Roc Cabriolet 5716
1 2 2 Removing and installing silencer, Arteon Passat, Passat Estate, Arteon Shooting Brake 5718
1 2 3 Removing and installing silencers, T-Roc with all-wheel drive 5720
1 2 4 Removing and installing silencers, T-Roc with front-wheel drive 5721
1 2 5 Removing and installing silencer, Touran 5723
1 2 6 Removing and installing silencer, Tiguan 5725
1 2 7 Removing and installing silencer, Polo, T-Cross 5728
1 2 8 Removing and installing silencer, Golf Estate 5730
1 3 Separating exhaust pipes from silencers 5731
1 4 Aligning exhaust system free of stress 5733
1 5 Checking exhaust system for leaks 5733
1 6 Installation position of clamp 5734
1 7 Assembly overview – front exhaust pipe 5735
1 7 1 Assembly overview – mounting for front exhaust pipe 5735
1 8 Removing and installing bracket for front exhaust pipe 5736
2 Emission control 5738
2 1 Assembly overview – emission control 5738
2 2 Removing and installing catalytic converter 5741
2 3 Removing and installing particulate filter 5746
2 4 Removing and installing exhaust flap control unit -J883- 5747
28 – Ignition system 5748
1 Ignition system 5748
1 1 Assembly overview – ignition system 5748
1 2 Removing and installing ignition coils with output stage 5750
1 3 Removing and installing knock sensor 1 -G61- 5754
1 4 Removing and installing engine speed sender -G28- 5755
1 5 Removing and installing inlet camshaft position sender -G1002- 5757
1 6 Removing and installing exhaust camshaft position sender -G1003- 5758
D4B8071B780 General body repairs interior 5760
00 – Technical data 5768
1 Safety information 5768
1 1 Safety measures when working on vehicles with a start/stop system 5768
1 2 Safety measures when working with pyrotechnic components 5769
1 3 Storage, transportation and disposal of airbag, belt tensioner and battery isolator units (pyrotechnic components) 5770
1 4 Additional safety regulations for side airbag 5771
1 5 Additional safety instructions for curtain airbag 5771
1 6 Safety regulations for crash sensors (pressure sensors) for front side airbags 5772
1 7 Renewing pyrotechnic, electrical and mechanical components of the restraint system after an accident 5772
1 8 Checking airbag securing parts after an accident 5774
1 9 Accident without airbag triggering 5774
1 10 Checking seat belts 5774
1 11 Check belt webbing 5775
1 12 Checking inertia reel (locking mechanism) 5776
1 13 Visually checking belt buckle 5777
1 14 Check operation of belt buckle 5777
1 15 Checking belt relays, and buckle tongues 5777
1 16 Checking securing parts and anchorage points after an accident 5777
1 17 Checking seat belt restraint function for holding additional child seats (not for driver’s seat belt) – country-specific 5778
1 18 Checking child seat anchors after an accident 5778
2 Repair instructions 5779
2 1 Contact corrosion 5779
2 2 Pipe/wire routing and attachment 5779
68 – Interior equipment 5780
1 Compartments/covers 5780
1 1 Overview of fitting locations – compartments/covers 5780
1 2 Assembly overview – dash panel cover on driver side 5781
1 3 Assembly overview – steering column trim 5782
1 3 1 Assembly overview – steering column trim, dash panel insert with analogue instruments 5782
1 3 2 Assembly overview – steering column trim, fully digital dash panel insert 5783
1 4 Assembly overview – glove compartment 5784
1 5 Assembly overview – storage compartment in headliner 5785
1 6 Removing and installing dash panel cover on driver side 5786
1 6 1 Removing and installing dash panel cover on driver side (dash panel insert with analogue instruments) 5786
1 6 2 Removing and installing gap cover of dash panel insert, fully digital dash panel insert 5787
1 7 Removing and installing upper steering column trim 5788
1 7 1 Removing and installing upper steering column trim, dash panel insert with analogue instruments 5788
1 7 2 Removing and installing upper steering column trim, fully digital dash panel insert 5789
1 8 Removing and installing lower steering column trim 5790
1 9 Removing and installing glove compartment opener 5791
1 10 Service position for glove compartment cover 5792
1 11 Removing and installing restrictor for glove compartment cover 5793
1 12 Removing and installing glove compartment 5795
1 13 Removing and installing glove compartment cover 5795
1 14 Removing and installing headliner storage compartment 5796
2 Equipment 5798
2 1 Assembly overview – net partition 5798
2 2 Assembly overview – sun visors 5799
2 3 Removing and installing net partition 5799
2 4 Removing and installing net partition mounting 5800
2 5 Removing and installing sun visor 5801
2 6 Removing and installing sun visor centre mount 5803
2 7 Removing and installing roof grab handle 5804
2 7 1 Assembly overview – roof grab handle 5804
2 7 2 Removing and installing roof grab handle 5804
2 8 Removing and installing grab handle bracket 5807
3 Centre console 5808
3 1 Removing and installing front ashtray 5808
3 2 Removing and installing rear centre console trim 5808
3 2 1 Removing and installing rear vent in centre console 5809
3 3 Removing and installing centre console trim in front footwell 5810
3 4 Removing and installing trim for operating and display unit 5811
3 5 Removing and installing centre console front storage compartment 5812
3 6 Removing and installing centre console insert 5812
3 7 Removing and installing centre console 5819
3 7 1 Removing and installing centre console 5819
3 8 Removing and installing centre console bracket 5824
3 8 1 Centre console bracket, removing and installing mounting bracket and insulation for selector mechanism 5824
4 Front centre armrest 5827
4 1 Removing and installing front centre armrest 5827
5 Interior mirror 5829
5 1 Assembly overview – interior mirror 5829
5 1 1 Assembly overview – manually operated anti-dazzle interior mirror 5829
5 1 2 Assembly overview – manually operated anti-dazzle interior mirror, with humidity sender -G355- 5829
5 1 3 Assembly overview – automatic anti-dazzle interior mirror with rain and light sensor -G397- 5830
5 1 4 Assembly overview – interior mirror with front camera for driver assist systems -R242- 5831
5 2 Removing and installing interior mirror 5833
5 2 1 Removing and installing manually operated anti-dazzle interior mirror 5833
5 2 2 Removing and installing manually operated anti-dazzle interior mirror with humidity sender -G355- 5833
5 2 3 Removing and installing automatic anti-dazzle interior mirror with rain and light sensor -G397- 5836
5 2 4 Removing and installing interior mirror with front camera for driver assist systems -R242- 5838
69 – Passenger protection 5841
1 Seat belts 5841
1 1 Overview of fitting locations – seat belts and anchorage points 5841
1 1 1 Overview of fitting locations – seat belts and anchorage points 5841
1 2 Assembly overview – front three-point seat belt 5843
1 2 1 Assembly overview – front three-point seat belt 5843
1 2 2 Assembly overview – front three-point seat belt, country-specific 5845
1 3 Assembly overview – rear outer three-point seat belt 5847
1 4 Assembly overview – rear centre three-point seat belt 5847
1 5 Assembly overview – front belt buckle 5848
1 6 Assembly overview – rear belt buckle 5849
1 7 Removing and installing front three-point seat belt 5851
1 8 Removing and installing rear three-point seat belt 5854
1 8 1 Removing and installing rear outer three-point seat belt 5854
1 8 2 Removing and installing rear centre three-point seat belt 5856
1 9 Removing and installing front belt guide 5856
1 10 Removing and installing rear belt guide 5857
1 11 Removing and installing front belt end fitting 5858
1 12 Removing and installing rear outer belt end fitting 5859
1 13 Removing and installing belt height adjuster 5860
1 14 Removing and installing front belt buckle 5861
1 15 Removing and installing rear belt buckle 5862
2 Child seat anchors 5864
2 1 Assembly overview – rear child seat anchors 5864
2 2 Removing and installing rear child seat anchors 5864
2 2 1 Removing and installing “ISOFIX child seat anchor” 5864
2 2 2 Removing and installing “top tether child seat anchor” 5865
2 2 3 Removing and installing child seat anchor, country-specific 5866
3 Airbag system 5868
3 1 Overview of fitting locations – airbag system 5868
3 1 1 Overview of fitting locations – airbag system 5868
4 Airbag control unit 5871
4 1 Assembly overview – airbag control unit 5871
4 2 Removing and installing airbag control unit -J234- 5871
5 Battery isolator igniter 5874
5 1 Assembly overview – battery isolator igniter 5874
5 2 Removing and installing battery isolator igniter 5874
6 Front airbag 5878
6 1 Assembly overview – front airbag, driver side 5878
6 2 Removing and installing airbag unit with igniter 5880
6 3 Renewing connector on airbag 5883
7 Front passenger airbag 5887
7 1 Assembly overview – front passenger airbag 5887
7 2 Removing and installing front passenger airbag unit with igniter 5889
7 3 Removing and installing key-operated switch to deactivate airbag on front passenger side 5891
8 Side airbags 5893
8 1 Assembly overview – front side airbag 5893
8 2 Assembly overview – rear side airbag 5895
8 3 Removing and installing front side airbag with igniter 5897
8 4 Removing and installing rear side airbag with igniter 5898
9 Curtain airbags 5900
9 1 Assembly overview – curtain airbag 5900
9 2 Removing and installing curtain airbag with igniter 5902
10 Knee airbags 5907
10 1 Assembly overview – knee airbag 5907
10 2 Removing and installing knee airbag with igniter 5908
11 Airbag crash sensors 5911
11 1 Overview of fitting locations – airbag crash sensors 5911
11 2 Removing and installing front airbag crash sensor 5913
11 3 Removing and installing front side airbag crash sensor -G179-/-G180- 5916
11 4 Removing and installing rear side airbag crash sensor -G256-/-G257- 5919
12 Seat belt verification 5922
12 1 Removing and installing Seat occupied sensor, front passenger side -G128- 5922
13 Pedestrian protection 5923
13 1 Assembly overview – pedestrian protection 5923
13 2 Removing and installing crash sensor for pedestrian protection -G570-/-G571- 5925
13 3 Removing and installing centre crash sensor for pedestrian protection -G693- 5927
13 4 Removing and installing trigger for pedestrian protection -G598-/-G599- 5929
13 5 Remove and installing front pressure hose sensor for pedestrian protection -G579- 5932
70 – Trim, insulation 5934
1 Front door trims 5934
1 1 Assembly overview – front door trim 5934
1 2 Removing and installing trim 5936
1 3 Removing and installing front door trim 5937
1 4 Removing and installing front armrest 5940
1 5 Removing and installing mirror cover trim 5941
2 Rear door trims 5944
2 1 Assembly overview – rear door trim 5944
2 2 Removing and installing trim 5945
2 3 Removing and installing rear door trim 5946
2 4 Removing and installing rear arm rest 5948
3 Dash panel 5950
3 1 Assembly overview – dash panel 5950
3 1 1 Assembly overview – dash panel, dash panel insert with analogue instruments 5950
3 1 2 Assembly overview – dash panel, fully digital dash panel insert 5951
3 2 Assembly overview – cover and trim for head-up display 5953
3 3 Removing and installing dash panel end cover 5953
3 4 Removing and installing dash panel trim 5955
3 4 1 Removing and installing dash panel trim with background lighting 5955
3 4 2 Removing and installing dash panel trim without background lighting 5957
3 4 3 Removing and installing dash panel trim on front passenger side (fully digital dash panel insert) 5958
3 4 4 Removing and installing dash panel trim on driver side (fully digital dash panel insert) 5960
3 5 Removing and installing loudspeaker trim 5960
3 6 Removing and installing radio/navigation system mounting frame 5961
3 6 1 Removing and installing radio/navigation system mounting frame, dash panel insert with analogue instruments 5961
3 6 2 Removing and installing radio/navigation system mounting frame, fully digital dash panel insert 5962
3 7 Removing and installing dash panel insert trim 5964
3 7 1 Removing and installing dash panel insert trim with analogue instruments 5964
3 7 2 Removing and installing fully digital dash panel insert trim 5965
3 8 Removing and installing dash panel 5966
3 9 Removing and installing outer dash panel vents 5972
3 10 Removing and installing cover for dash panel/head-up display 5974
3 10 1 Removing and installing trim for head-up display 5974
3 10 2 Removing and installing cover for dash panel/head-up display 5975
4 Dash panel cross member 5977
4 1 Assembly overview – central tube for dash panel 5977
4 2 Removing and installing dash panel cross member 5977
4 3 Removing and installing crash bar 5982
5 Interior trims 5983
5 1 Overview of fitting locations – interior trims 5983
5 1 1 Overview of fitting locations – interior trims, Arteon 5983
5 1 2 Overview of fitting locations – interior trims, Arteon Shooting Brake 5984
5 2 Assembly overview – sill panel mouldings 5986
5 2 1 Assembly overview – sill panel mouldings, Arteon 5986
5 2 2 Assembly overview – sill panel mouldings, Arteon Shooting Brake 5987
5 3 Assembly overview – A-pillar trim 5987
5 3 1 Assembly overview – A-pillar trim, upper A-pillar trim 5987
5 3 2 Assembly overview – A-pillar trim, lower A-pillar trim, LHD vehicles 5988
5 3 3 Assembly overview – A-pillar trim, lower A-pillar trim, RHD vehicles 5989
5 4 Assembly overview – B-pillar trim 5990
5 5 Assembly overview – C-pillar trim 5991
5 5 1 Assembly overview – C-pillar trim, Arteon 5991
5 5 2 Assembly overview – C-pillar trim, Arteon Shooting Brake 5992
5 6 Assembly overview – D-pillar trim 5993
5 7 Assembly overview – foot rest and floor covering 5994
5 7 1 Assembly overview – foot rest and floor covering, left-hand drive vehicle 5994
5 7 2 Assembly overview – foot rest and floor covering, right-hand drive vehicle 5995
5 8 Removing and installing sill panel moulding 5996
5 9 Removing and installing A-pillar gap cover 5998
5 10 Removing and installing A-pillar trim 5999
5 10 1 Removing and installing A-pillar trim, upper A-pillar trim 5999
5 10 2 Removing and installing A-pillar trim, lower A-pillar trim, driver side, LHD vehicles 6001
5 10 3 Removing and installing A-pillar trim, lower A-pillar trim, driver side, RHD vehicles 6002
5 10 4 Removing and installing A-pillar trim, lower A-pillar trim, front passenger side 6003
5 11 Removing and installing B-pillar trim 6004
5 12 Removing and installing C-pillar trim 6007
5 12 1 Removing and installing C-pillar trim, Arteon 6007
5 12 2 Removing and installing C-pillar trim, Arteon Shooting Brake 6008
5 13 Removing and installing D-pillar trim 6010
5 14 Removing and installing rear sill panel moulding 6011
5 14 1 Removing and installing rear sill panel moulding, Arteon 6011
5 14 2 Removing and installing rear sill panel moulding, Arteon Shooting Brake 6014
5 15 Removing and installing foot rest 6016
5 15 1 Removing and installing foot rest, left-hand drive vehicle 6016
5 15 2 Removing and installing foot rest, RHD vehicles 6017
5 16 Removing and installing floor covering 6018
6 Luggage compartment trims 6020
6 1 Overview of fitting locations – luggage compartment trims 6020
6 1 1 Overview of fitting locations – luggage compartment trims, Arteon 6020
6 1 2 Overview of fitting locations – luggage compartment trims, Arteon Shooting Brake 6021
6 2 Assembly overview – luggage compartment side trim 6023
6 2 1 Assembly overview – luggage compartment side trim, Arteon 6023
6 2 2 Assembly overview – luggage compartment left side trim, Arteon Shooting Brake 6024
6 2 3 Assembly overview – luggage compartment right side trim, Arteon Shooting Brake 6025
6 3 Assembly overview – luggage compartment floor 6027
6 3 1 Assembly overview – luggage compartment floor, Arteon 6027
6 3 2 Assembly overview – luggage compartment floor, Arteon Shooting Brake 6027
6 3 3 Assembly overview – luggage compartment floor Arteon PHEV and Arteon Shooting Brake PHEV 6028
6 4 Assembly overview – lower rear lid trim 6029
6 4 1 Assembly overview – lower rear lid trim, Arteon 6029
6 4 2 Assembly overview – lower rear lid trim, Arteon Shooting Brake 6030
6 5 Assembly overview – upper rear lid trim 6031
6 5 1 Assembly overview – upper rear lid trim, Arteon 6031
6 5 2 Assembly overview – upper rear lid trim, Arteon Shooting Brake 6032
6 6 Removing and installing lower rear lid trim 6033
6 6 1 Removing and installing lower rear lid trim, Arteon 6033
6 6 2 Removing and installing lower rear lid trim, Arteon Shooting Brake 6035
6 7 Removing and installing luggage compartment cover 6036
6 8 Removing and installing manual release mechanism for rear lid, country-specific version “NAR” 6037
6 9 Removing and installing upper rear lid trim 6038
6 9 1 Removing and installing upper rear lid trim, Arteon 6038
6 9 2 Removing and installing upper rear lid trim, Arteon Shooting Brake 6039
6 10 Removing and installing luggage compartment side trim 6041
6 10 1 Removing and installing luggage compartment side trim, Arteon 6041
6 10 2 Removing and installing luggage compartment side trim, Arteon Shooting Brake 6043
6 11 Removing and installing lock carrier trim 6044
6 12 Removing and installing fastening rings 6045
7 Roof trims 6047
7 1 Assembly overview – moulded headliner 6047
7 2 Assembly overview – moulded headliner 6047
7 3 Removing and installing moulded headliner 6048
7 4 Installing roof reinforcement to body 6052
7 4 1 Installing roof reinforcement to body without sliding sunroof, Arteon 6052
7 4 2 Installing roof reinforcement to body with sliding sunroof, Arteon 6056
7 4 3 Installing roof reinforcement on body without sliding sunroof, Arteon Shooting Brake 6059
7 4 4 Installing roof reinforcement on body without sliding sunroof, Arteon Shooting Brake 6062
72 – Seat frames 6065
1 Overview of seat variants 6065
1 1 Overview of fitting locations – seat variants 6065
1 2 Securing front seat to seat repair stand 6066
2 Front seats 6068
2 1 Overview of fitting locations – electrical and electronic components 6068
2 1 1 Overview of fitting locations – electrical and electronic components, standard seat, ergo comfort seat 6069
2 1 2 Overview of fitting locations – electrical and electronic components, electrically adjustable seat 6071
2 1 3 Overview of fitting locations – electrical and electronic components, electrically adjustable seat with seat ventilation 6073
2 2 Assembly overview – front seat 6075
2 2 1 Assembly overview – front seat, standard seat, ergo comfort seat 6075
2 2 2 Assembly overview – front seat, electrically adjustable seat 6077
2 3 Assembly overview – front backrest 6079
2 3 1 Assembly overview – front backrest, standard seat, ergo comfort 6079
2 3 2 Assembly overview – front backrest with seat ventilation 6080
2 3 3 Assembly overview – front backrest, electrically adjustable lumbar support 6082
2 4 Assembly overview – seat pan 6083
2 4 1 Assembly overview – seat pan, standard seat, ergo comfort seat 6083
2 4 2 Assembly overview – seat pan, electrically adjustable seat 6085
2 4 3 Assembly overview – seat pan, with seat ventilation 6087
2 4 4 Assembly overview – seat pan, torsion rod 6087
2 5 Assembly overview – seat height adjustment 6088
2 5 1 Assembly overview – seat height adjustment, manual seat height adjustment 6088
2 5 2 Assembly overview – seat height adjustment, electrical seat height adjustment 6089
2 6 Assembly overview – seat rake adjustment 6090
2 6 1 Assembly overview – seat rake adjustment, manual seat rake adjustment 6090
2 6 2 Assembly overview – seat rake adjustment, electrical seat rake adjustment 6091
2 7 Assembly overview – seat depth adjustment 6092
2 8 Assembly overview – fire extinguisher 6093
2 9 Removing and installing front seat 6094
2 9 1 Removing and installing front seat 6094
2 9 2 Removing and installing front seat if seat longitudinal adjustment motor -V28-/-V31- is defective 6097
2 10 Connecting and disconnecting airbag adapter 6101
2 11 Removing and installing seat trim 6102
2 11 1 Removing and installing seat trim on tunnel side 6102
2 11 2 Removing and installing seat trim on sill side 6103
2 12 Removing and installing bracket for seat trim 6105
2 13 Removing and installing manually adjustable lumbar support frame 6105
2 14 Removing and installing seat depth adjuster 6107
2 15 Removing and installing seat height adjustment handle 6112
2 16 Removing and installing seat height adjuster 6113
2 16 1 Removing and installing seat height adjustment unit, manual seat height adjustment 6113
2 16 2 Removing and installing seat height adjustment unit, electric seat height adjustment 6114
2 17 Removing and installing lower seat pan frame with seat longitudinal adjustment motor -V28-/-V31- 6114
2 18 Removing and installing lumbar support adjuster 6115
2 19 Removing and installing front backrest 6116
2 20 Removing and installing head restraint 6118
2 21 Removing and installing head restraint guide 6120
2 22 Removing and installing lumbar support adjustment switch -E176-/-E177- 6120
2 23 Removing and installing lumbar support adjustment motor -V125-/-V126-/-V129-/-V130- 6121
2 24 Removing and installing seat adjustment operating unit -E470-/-E471- 6122
2 25 Removing and installing massage control unit -J740- 6123
2 26 Removing and installing seat adjustment control unit 6124
2 27 Removing and installing impact and stabbing protector in backrest 6124
2 28 Removing and installing backrest adjustment handle 6126
3 Rear seats 6128
3 1 Assembly overview – bench seat/individual seats 6128
3 2 Assembly overview – locking mechanism 6129
3 3 Assembly overview – rear seat backrest 6130
3 4 Assembly overview – centre armrest 6132
3 5 Assembly overview – side padding 6134
3 6 Removing and installing bench seat/individual seats 6134
3 7 Removing and installing head restraint 6136
3 8 Removing and installing head restraint guide 6137
3 9 Removing and installing rear seat backrest 6138
3 10 Removing and installing locking mechanism trim 6140
3 11 Removing and installing locking mechanism for rear seat backrest 6141
3 12 Removing and installing trim frame for load-through hatch 6142
3 13 Removing and installing flap for load-through hatch 6144
3 14 Removing and installing centre armrest 6145
3 15 Removing and installing side padding 6145
74 – Seat – padding, covers 6146
1 Front seat covers and padding 6146
1 1 Assembly overview – seat pan cover and padding 6146
1 1 1 Assembly overview – seat pan cover and padding 6146
1 1 2 Assembly overview – cover and padding for seat pan, seat depth adjustment 6147
1 2 Assembly overview – cover and backrest padding 6148
1 3 Assembly overview – seat heating element 6149
1 4 Removing and installing cover and padding in area of seat pan 6150
1 5 Removing and installing backrest cover and backrest padding 6154
1 6 Separating cover and padding in area of seat pan 6161
1 7 Separating cover and padding on backrest 6164
1 8 Removing and installing seat heating element -Z6-/-Z8- 6168
1 9 Removing and installing backrest heating element -Z7-/-Z9- 6169
2 Rear seat covers and padding 6170
2 1 Assembly overview – rear bench seat cover and padding 6170
2 2 Assembly overview – rear seat backrest cover and padding 6171
2 3 Assembly overview – seat heating element 6172
2 4 Removing and installing cover and padding of rear bench seat 6173
2 5 Removing and installing cover and padding of rear seat backrest 6174
2 6 Removing and installing intermediate padding, backrest with load-through hatch 6177
2 7 Separating rear bench seat cover and padding 6178
2 8 Separating cover and padding of rear seat backrest 6179
2 9 Removing and installing seat heating element 6179
2 10 Removing and installing backrest heating element 6180
D4B8071EF84 Communication 6182
00 – Technical data 6186
1 Repair notes 6186
1 1 General repair instructions 6186
1 2 Routing and attachment of lines 6186
1 3 Notes on repair of CAN bus wiring 6186
1 4 General notes 6186
91 – Communication 6188
1 Infotainment system 6189
1 1 Components of infotainment system 6189
1 2 Overview of fitting locations – Infotainment system 6190
1 3 Removing and installing infotainment system display 6191
1 4 Removing and installing control unit 1 for information electronics -J794- 6193
1 5 Renewing rotary knobs of display unit for front information display and operating unit control unit -J685- 6194
2 Sound system 6196
2 1 Components of sound system 6196
2 2 Overview of fitting locations – sound system 6197
2 3 Removing and installing digital sound package control unit/amplifier 6198
2 4 Removing and installing retainer for digital sound package control unit -J525- 6200
2 5 Removing and installing front treble loudspeakers -R20-/-R22- 6200
2 6 Removing and installing rear treble loudspeakers -R14-/-R16- 6200
2 7 Removing and installing front mid-range loudspeakers 6201
2 8 Removing and installing front bass loudspeakers -R21-/-R23- 6202
2 9 Removing and installing rear bass loudspeakers -R15-/-R17- 6203
2 10 Removing and installing subwoofer -R211- 6204
2 11 Removing and installing centre loudspeaker 6205
3 Aerial systems 6207
3 1 Components of aerial systems 6207
3 2 Overview of fitting locations – aerial systems 6207
3 3 Removing and installing aerial module 6209
3 4 Removing and installing aerial amplifier 6210
3 5 Removing and installing frequency modulation (FM) frequency filter in negative wire -R178- 6211
3 6 Removing and installing frequency modulation (FM) frequency filter in positive wire -R179- 6212
3 7 Removing and installing roof aerial 6213
3 8 Removing and installing bumper aerials 6214
3 8 1 Removing and installing bumper aerials, vehicles without towing bracket 6214
3 8 2 Removing and installing bumper aerials, vehicles with towing bracket 6215
4 Radio 6217
4 1 Components of radio system 6217
4 2 Removing and installing radio 6217
5 Telephone system 6218
5 1 Mobile telephone preparation 6218
5 1 1 Mobile telephone preparation, Bluetooth hands-free system 6218
5 1 2 Preparation for mobile telephone, Bluetooth hands-free system, Comfort 6219
5 1 3 Preparation for mobile telephone, on-line Bluetooth hands-free system 6219
5 2 Overview of fitting locations – telephone system 6220
5 3 Removing and installing telephone microphone -R38- 6221
5 3 1 Removing and installing telephone microphone -R38-, except for »panel light« 6221
5 3 2 Removing and installing telephone microphone -R38-, »panel light« only 6222
5 4 Removing and installing two-way signal amplifier for mobile telephone/data services -J984- 6223
5 5 Removing and installing storage compartment with interface for mobile telephone -R265- 6223
6 Navigation system 6224
6 1 Components of navigation system 6224
6 2 Overview of fitting locations – navigation system 6224
6 3 Removing and installing control unit for navigation system 6225
7 TV system 6226
7 1 Overview of fitting locations – TV system 6226
7 2 Removing and installing TV tuner 6226
8 Reversing camera system 6229
8 1 Components of reversing camera system 6229
8 2 Overview of fitting locations – reversing camera system 6229
8 3 Removing and installing reversing camera -R189- 6230
8 4 Removing and installing reversing camera system control unit -J772- 6230
8 5 Calibrating reversing camera system 6231
8 5 1 Assembling and setting-up calibration unit -VAS 6350- 6231
8 5 2 Calibrating reversing camera -R189- 6233
9 Multifunction steering wheel 6237
9 1 Components of multifunction steering wheel 6237
9 2 Assembly overview – multifunction steering wheel 6237
9 3 Removing and installing steering wheel multifunction buttons -E441-/-E440- 6238
9 4 Removing and installing Tiptronic switch in steering wheel -E439-/-E438- 6241
10 Connection for external multimedia devices 6243
10 1 Removing and installing connection for external multimedia devices 6243
10 1 1 Removing and installing connection for external multimedia devices, USB connection 1 -U41- and connection for external audio sources -R199- in centre console storage compartment at rear 6243
10 1 2 Removing and installing connection for external multimedia devices, USB connection 2 -U42- in centre console storage compartment at front 6244
10 2 Removing and installing USB charging socket 1 -U37- 6245
10 3 Removing and installing USB hub -R293- 6245
11 Car-Net 6247
11 1 General notes 6247
11 2 Overview of fitting locations – Car-Net services 6247
11 3 Removing and installing emergency call module control unit and communication unit -J949- 6248
11 4 Removing and installing telematics button module -E734- 6250
11 5 Removing and installing loudspeaker for emergency call module -R335- 6250
11 6 Renewing control unit for emergency call module and communication unit -J949- 6251
11 7 Renewing battery in emergency call module control unit and communication unit -J949- 6251
11 8 Commissioning ERA Glonass 6253
12 Overhead view camera 6254
12 1 Overview – overhead view camera 6254
12 2 Overview of fitting locations – overhead view camera 6254
12 3 Removing and installing overhead view camera control unit -J928- 6255
12 4 Removing and installing front overhead view camera -R243- 6256
12 5 Removing and installing left overhead view camera -R244- 6257
12 6 Removing and installing right overhead view camera -R245- 6258
12 7 Removing and installing rear overhead view camera -R246- 6258
12 8 Calibrating overhead view camera 6258
12 8 1 Assembling and setting-up calibration unit -VAS 721 001- 6258
12 8 2 Calibrating overhead view camera system 6260
D4B8071F11E General body repairs exterior 6263
00 – Technical data 6271
1 Safety notes 6271
1 1 Safety precautions when working on vehicles with a start/stop system 6271
1 2 Repair notes 6271
1 2 1 General information for use of adhesives 6271
1 2 2 Preparations for installation of self-adhesive components 6272
50 – Body – front 6274
1 Lock carrier 6274
1 1 Assembly overview – lock carrier 6274
1 2 Removing and installing lock carrier 6276
1 3 Setting service position and returning to normal position 6278
2 Wing 6283
2 1 Assembly overview – wing 6283
2 2 Removing and installing wing 6283
3 Bulkhead 6289
3 1 Assembly overview – bulkhead 6289
3 2 Assembly overview – plenum chamber cover 6289
3 3 Removing and installing bulkhead 6290
3 4 Removing and installing plenum chamber cover 6291
55 – Bonnet, rear lid 6294
1 Bonnet 6294
1 1 Assembly overview – bonnet 6294
1 2 Assembly overview – Bowden cable 6296
1 3 Removing and installing bonnet 6298
1 4 Adjusting bonnet 6301
1 5 Removing and installing bonnet lock 6306
1 5 1 Removing and installing left bonnet lock 6306
1 5 2 Removing and installing right bonnet lock 6309
1 6 Removing and installing bonnet lock release lever 6311
1 7 Removing and installing striker pin 6313
1 8 Removing and installing hinges 6314
1 9 Removing and installing insulation 6317
1 10 Removing and installing gas strut 6318
1 11 Releasing gas from gas strut 6320
1 12 Removing and installing Bowden cable 6321
1 12 1 Removing and installing Bowden cable to mounting bracket 6321
1 12 2 Removing and installing Bowden cable from right bonnet lock to release mechanism 6323
1 12 3 Removing and installing Bowden cable from left bonnet lock to release mechanism 6324
1 12 4 Removing and installing Bowden cable coupling with Bowden cables 6327
1 13 Resetting hinge 6328
2 Rear lid 6330
2 1 Assembly overview – rear lid 6330
2 1 1 Assembly overview – rear lid, Arteon 6330
2 1 2 Assembly overview – rear lid, Arteon Shooting Brake 6332
2 1 3 Overview of fitting locations – electric rear lid 6334
2 2 Removing and installing rear lid 6335
2 2 1 Removing and installing rear lid – Arteon 6335
2 2 2 Removing and installing rear lid – Arteon Shooting Brake 6339
2 3 Adjusting rear lid 6342
2 4 Removing and installing bonnet lock 6349
2 4 1 Removing and installing bonnet lock 6349
2 4 2 Removing and installing rear lid lock with power latching system 6351
2 4 3 Installing new lid lock with power latching system 6355
2 4 4 Removing and installing power latching system on rear lid 6357
2 4 5 Installing new power latching system for rear lid 6360
2 5 Removing and installing actuating mechanism 6361
2 5 1 Removing and installing handle, without reversing camera 6361
2 5 2 Removing and installing handle, with reversing camera 6363
2 6 Removing and installing hinges 6365
2 6 1 Removing and installing hinges – Arteon 6365
2 6 2 Removing and installing hinges – Arteon Shooting Brake 6367
2 7 Removing and installing striker pin 6370
2 8 Removing and installing rear lid seal 6371
2 8 1 Removing and installing rear lid seal 6371
2 8 2 Removing and installing gap seal 6373
2 9 Removing and installing gas strut 6375
2 9 1 Removing and installing exposed gas strut – Arteon 6375
2 9 2 Removing and installing covered gas strut – Arteon Shooting Brake 6377
2 10 Releasing gas from gas strut 6379
2 10 1 Releasing gas from gas strut 6379
2 10 2 Releasing gas from gas strut with cover 6380
2 11 Removing and installing rear lid drive unit -VX69- 6381
2 11 1 Removing and installing rear lid drive unit -VX69- – Arteon 6381
2 11 2 Removing and installing rear lid drive unit -VX69- – Arteon Shooting Brake 6385
2 12 Preparing rear lid drive unit VX69/rear lid drive unit 2 VX77 for disposal 6387
3 Tank flap unit 6389
3 1 Assembly overview – tank flap unit 6389
3 2 Removing and installing tank flap unit 6389
3 3 Removing and installing fuel tank flap 6392
4 Charging flap unit 6395
4 1 Assembly overview – charging flap unit 6395
4 2 Removing and installing charging flap unit 6395
4 2 1 Removing and installing immediate charging button -E766- 6396
57 – Front doors, door components, central locking 6398
1 Door 6398
1 1 Assembly overview – door 6398
1 2 Assembly overview – door seals 6401
1 3 Removing and installing inner door seal 6402
1 3 1 Removing and installing inner door seal 6402
1 3 2 Removing and installing retaining frame 6405
1 4 Removing and installing outer door seal 6407
1 4 1 Removing and installing outer door seal 6407
1 4 2 Removing and installing door joint seal 6409
1 5 Removing and installing door 6410
1 6 Adjusting door 6412
1 7 Adjusting striker pin 6414
1 8 Removing and installing door arrester 6416
2 Door components 6419
2 1 Assembly overview – door components 6419
2 2 Assembly overview – window regulator 6421
2 3 Assembly overview – door handle and door lock 6421
2 4 Removing and installing window regulator motor 6423
2 5 Removing and installing window regulator 6425
2 6 Removing and installing inner door cover 6427
2 7 Removing and installing striker pin 6429
2 8 Removing and installing cap on door handle 6431
2 8 1 Removing and installing cap for door handle, with lock cylinder 6431
2 8 2 Removing and installing cap for door handle, without lock cylinder 6433
2 9 Removing and installing lock cylinder 6437
2 10 Removing and installing door handle 6441
2 10 1 Removing and installing door handle 6441
2 10 2 Removing and installing door handle with keyless entry system 6443
2 11 Removing and installing mounting bracket 6445
2 12 Removing and installing door lock 6447
2 13 Removing and installing window channel 6451
2 14 Removing and installing outer window slot seal 6454
2 15 Removing and installing window slot inner seal 6456
3 Central locking 6458
3 1 Overview of fitting locations – central locking system 6458
3 2 Assembly overview – ignition key 6460
3 3 Removing and installing driver door control unit -J386- and front passenger door control unit -J387- 6461
3 4 Removing and installing rear left door control unit -J926- and rear right door control unit -J927- 6463
3 5 Removing and installing tank filler flap locking motor -V155- 6464
3 6 Removing and installing actuator for high-voltage charging flap lock 1 -F496- 6465
3 7 Removing and installing ignition key battery 6466
3 8 Removing and installing cap on ignition key 6467
58 – Rear doors, door components 6469
1 Door 6469
1 1 Assembly overview – door 6469
1 2 Assembly overview – door seals 6472
1 3 Removing and installing door 6473
1 4 Adjusting door 6476
1 5 Adjusting striker pin 6477
1 6 Removing and installing door arrester 6479
1 7 Removing and installing inner door seal 6481
1 7 1 Removing and installing inner door seal 6481
1 7 2 Removing and installing retaining strip 6484
1 8 Removing and installing outer door seal 6486
1 8 1 Removing and installing outer door seal 6486
1 8 2 Removing and installing door joint seal 6488
2 Door components 6490
2 1 Assembly overview – door components 6490
2 2 Assembly overview – window regulator 6491
2 3 Assembly overview – door handle and door lock 6492
2 4 Removing and installing window regulator motor 6493
2 5 Removing and installing window regulator 6497
2 6 Removing and installing inner door cover 6499
2 7 Removing and installing striker pin 6501
2 8 Removing and installing cap on door handle 6503
2 9 Removing and installing door handle 6507
2 9 1 Removing and installing door handle 6507
2 9 2 Removing and installing door handle with keyless entry system 6509
2 10 Removing and installing mounting bracket 6512
2 11 Removing and installing door lock 6514
2 12 Removing and installing outer window slot seal 6518
2 13 Removing and installing window slot inner seal 6520
60 – Sunroof 6522
1 Sliding sunroof 6522
1 1 Assembly overview – sliding sunroof 6522
1 2 Assembly overview – sunroof roller blind 6524
1 3 Removing and installing sliding sunroof frame 6525
1 3 1 Minimum curing period 6525
1 3 2 Fitting instructions 6525
1 3 3 Removing soiling caused by adhesive sealant 6526
1 3 4 Touching up paint damage 6526
1 3 5 Materials 6526
1 3 6 Preparing body flange for bonding 6527
1 3 7 Preparing sliding sunroof frame for installation 6528
1 3 8 Removing and installing sliding sunroof frame 6530
1 4 Removing and installing wind deflector 6535
1 5 Removing and installing glass panel 6537
1 5 1 Removing and installing glass panel 6537
1 5 2 Removing glass panel when drive is defective 6540
1 6 Adjusting sliding sunroof panel 6542
1 7 Removing and installing slotted guide 6544
1 8 Removing and installing front trim for sliding sunroof 6550
1 8 1 Minimum curing period 6550
1 8 2 Fitting instructions 6550
1 8 3 Removing soiling caused by adhesive sealant 6550
1 8 4 Materials 6551
1 8 5 Preparing front trim for installation 6551
1 8 6 Preparing sliding sunroof frame for installation of front trim 6553
1 8 7 Removing and installing front trim for sliding sunroof 6554
1 9 Removing and installing sliding sunroof motor -V1- 6559
1 10 Removing and installing sliding sunroof adjustment control unit -J245- 6563
1 11 Removing and installing sliding sunroof seals 6567
1 11 1 Removing and installing seal for sliding sunroof frame 6567
1 11 2 Removing and installing glass panel seal 6568
1 12 Removing and installing sunroof roller blind 6569
1 13 Programming sliding sunroof adjustment control unit -J245- 6578
2 Sliding sunroof 6580
2 1 Assembly overview – sliding sunroof 6580
2 2 Assembly overview – sliding sunroof seals 6582
2 3 Removing and installing sliding sunroof panel 6582
2 4 Removing and installing rear sliding sunroof panel 6586
2 5 Adjusting sliding sunroof panel 6591
2 5 1 Checking height adjustment 6591
2 5 2 Adjusting front glass panel 6592
2 5 3 Adjusting rear glass panel 6593
2 6 Removing and installing sliding sunroof seals 6594
2 6 1 Removing and installing the exterior seal 6594
2 6 2 Removing and installing outer seal for rear glass panel 6598
2 6 3 Removing and installing additional seal for rear glass panel 6598
2 7 Removing and installing wind deflector 6599
2 8 Removing and installing sliding sunroof motor -V1- 6603
2 9 Removing and installing sunroof roller blind motor -V260- 6605
2 10 Removing and installing sunroof roller blind control unit -J394- 6607
2 11 Removing and installing sliding sunroof adjustment control unit -J245- 6608
2 12 Removing and installing sunroof roller blind 6610
2 13 Removing and installing sliding sunroof frame 6614
2 14 Manual actuation 6617
2 14 1 Glass panel 6617
2 14 2 Sun blind 6618
3 Water drain hoses 6619
3 1 Assembly overview – water drain hoses 6619
3 2 Cleaning water drain hoses 6619
3 3 Removing and installing water drain hoses 6621
4 Water drain hoses 6623
4 1 Assembly overview – water drain hoses 6623
4 2 Cleaning water drain hoses 6623
4 3 Removing and installing water drain hoses 6625
63 – Bumpers 6627
1 Bumper, front 6627
1 1 Assembly overview – bumper cover 6627
1 1 1 Assembly overview – bumper cover, vehicles ► 08 2020 6627
1 1 2 Assembly overview – bumper cover, vehicles 09 2020 ► 6629
1 1 3 Assembly overview – bumper cover, R-Line 6632
1 1 4 Assembly overview – bumper cover, R-Line, NAR 6634
1 1 5 Assembly overview – bumper cover, R model 6636
1 2 Assembly overview – bumper carrier 6638
1 3 Removing and installing bumper cover 6639
1 4 Removing and installing attachments 6644
1 4 1 Removing and installing number plate carrier 6644
1 4 2 Removing and installing bumper cover (part section) 6646
1 4 3 Removing and installing bumper cover part section, R-Line 6648
1 4 4 Removing and installing side guides 6649
1 4 5 Removing and installing lateral guides, R-Line 6651
1 4 6 Removing and installing air ducts 6652
1 4 7 Removing and installing air ducts, R-Line 6654
1 4 8 Removing and installing spoilers 6655
1 4 9 Removing and installing spoiler, R-Line 6656
1 5 Repairing bumper cover 6658
1 6 Installing holder for parking aid sender 6658
1 6 1 Installing bracket for parking aid – in bumper cover 6658
1 6 2 Removing and installing bracket for parking aid – in air ventilation grille 6663
1 7 Installing bracket for parking aid sender 6664
2 Bumper, rear 6668
2 1 Assembly overview – bumper cover 6668
2 1 1 Assembly overview – bumper cover 6668
2 1 2 Assembly overview – bumper cover, R model 6670
2 2 Assembly overview – bumper carrier 6671
2 3 Removing and installing bumper cover 6671
2 4 Removing and installing bumper carrier 6674
2 5 Repairing bumper cover 6675
2 6 Installing holder for parking aid sender 6676
2 7 Installing bracket for parking aid sender 6681
64 – Glazing 6685
1 Repair notes 6685
1 1 Minimum drying times for bonded windows 6685
1 2 Window repair 6685
1 3 Installation instructions for bonded windows 6686
1 3 1 Fitting instructions 6686
1 3 2 Materials 6687
1 4 Preparing old undamaged windows for installing 6688
1 5 Preparing new windows for installing 6689
1 6 Preparing body flange for installing 6690
1 7 Cleaning off excess adhesive 6692
2 Windscreen 6693
2 1 Assembly overview – windscreen 6693
2 2 Removing and installing windscreen 6694
2 2 1 Removing and installing windscreen 6694
2 2 2 Removing broken windscreen 6700
3 Rear windscreen 6701
3 1 Assembly overview – rear window 6701
3 2 Removing and installing rear window 6702
3 2 1 Removing and installing rear window 6702
3 2 2 Removing broken rear window 6705
4 Rear windscreen 6706
4 1 Assembly overview – rear window 6706
4 2 Removing and installing rear window 6707
4 2 1 Removing and installing rear window 6707
4 2 2 Removing broken rear window 6710
5 Side windows 6711
5 1 Assembly overview – rear side window 6711
5 1 1 Assembly overview – rear side window, Arteon 6711
5 1 2 Assembly overview – rear side window, Arteon Shooting Brake 6711
5 2 Removing and installing rear side window 6712
5 2 1 Removing and installing rear side window 6712
5 2 2 Removing damaged rear side window 6716
6 Door windows 6717
6 1 Assembly overview – front door window 6717
6 2 Assembly overview – rear door window 6717
6 3 Removing and installing front door window 6718
6 4 Adjusting front door window 6721
6 4 1 Notes for adjustment 6721
6 4 2 Basic height adjustment 6721
6 4 3 Adjusting longitudinally 6723
6 4 4 Checking height, adjusting if necessary 6724
6 4 5 Adjusting inclination 6728
6 5 Removing and installing rear door window 6729
6 6 Adjusting rear door window 6732
6 6 1 Notes for adjustment 6732
6 6 2 Basic height adjustment 6732
6 6 3 Adjusting longitudinally 6734
6 6 4 Checking height, adjusting if necessary 6735
6 6 5 Adjusting inclination 6738
66 – Exterior equipment 6740
1 Radiator grille and front trim 6740
1 1 Assembly overview – radiator grille 6740
1 2 Removing and installing radiator grille 6740
2 Spoiler 6743
2 1 Assembly overview – spoilers 6743
2 2 Removing and installing spoilers 6743
2 2 1 Repair notes 6743
2 2 2 Removing and installing rear lid spoiler 6744
3 Spoiler 6749
3 1 Assembly overview – spoilers 6749
3 2 Removing and installing spoilers 6750
3 3 Removing and installing side spoiler 6752
4 Mouldings, trims, extensions 6756
4 1 Assembly overview – trim strip and covers 6756
4 1 1 Assembly overview – trim strip and covers 6756
4 1 2 Assembly overview – roof trim strip and seal 6757
4 2 Assembly overview – side member trim 6758
4 3 Assembly overview – water deflector strip 6759
4 4 Assembly overview – trim panel for A-pillar 6760
4 5 Assembly overview – trim panel for B-pillar 6761
4 6 Removing and installing trim strip 6762
4 6 1 Removing and installing trim strip on door trim cover 6762
4 6 2 Removing and installing roof trim strip 6765
4 6 3 Removing and installing seal for roof trim strip 6767
4 6 4 Removing and installing trim strip of rear lid 6769
4 7 Removing and installing cover 6771
4 8 Removing and installing side member trim 6775
4 9 Removing and installing water deflector strip 6777
4 10 Removing and installing trim panel for A-pillar 6778
4 11 Removing and installing trim panel for B-pillar 6779
5 Noise insulation 6783
5 1 Assembly overview – noise insulation 6783
5 1 1 Assembly overview – short noise insulation 6783
5 1 2 Assembly overview – long noise insulation 6784
5 1 3 Assembly overview – skid plate 6784
6 Underbody cladding 6786
6 1 Overview of fitting locations – underbody cladding 6786
6 1 1 Assembly overview – underbody cladding 6786
6 1 2 Assembly overview – low-noise underbody cladding 1/3 6787
6 1 3 Assembly overview – low-noise underbody cladding 2/3 6788
6 1 4 Assembly overview – low-noise underbody cladding 3/3 6789
6 2 Assembly overview – underbody struts 6790
6 3 Removing and installing underbody cladding 6791
6 3 1 Removing and installing underbody cladding 6791
6 3 2 Removing and installing rear underbody cladding 6793
6 4 Removing and installing tunnel cross-piece 6794
7 Trim film and protective film 6798
7 1 Renewing protective films 6798
8 Exterior mirror 6800
8 1 Assembly overview – exterior mirror 6800
8 2 Removing and installing exterior mirror 6802
8 3 Removing and installing mirror glass 6803
8 4 Removing and installing mirror adjustment unit 6805
8 5 Removing and installing mirror cover 6807
8 6 Removing and installing mirror frame 6808
9 Wheel housing liner 6809
9 1 Assembly overview – front wheel housing liner 6809
9 2 Assembly overview – rear wheel housing liner 6810
9 3 Removing and installing front wheel housing liner 6810
9 4 Removing and installing rear wheel housing liner 6813
10 Lettering and badges 6817
10 1 Dimensions – lettering and badges on rear 6817
10 1 1 Dimensions – lettering on rear 6817
10 1 2 Dimensions – additional lettering at rear, vehicles 09 2020 ► 6818
10 1 3 Dimensions – badges at rear, R model 6819
10 2 Removing and installing front badges 6820
10 2 1 Removing and installing manufacturer emblem 6820
10 3 Removing and installing lettering 6821
10 4 Renewing lettering and badges at rear 6823
10 5 Renewing lettering and badges on sides 6824
10 6 Removing and installing lettering and badges for radiator grille 6825
11 Special add-on parts 6827
11 1 Assembly overview – special add-on parts 6827
12 Towing bracket 6828
12 1 Assembly overview – towing bracket 6828
12 2 Removing and installing towing bracket 6830
12 3 Removing and installing trigger unit 6832
13 Heat shields 6834
13 1 Overview of fitting locations – heat shields 6834
13 2 Removing and installing underbody heat shield 6834
13 2 1 Removing and installing tunnel heat shield 6834
13 2 2 Removing and installing propshaft heat shield 6836
13 2 3 Removing and installing rear underbody heat shield 6836
13 2 4 Removing and installing centre silencer heat shield 6837
13 2 5 Removing and installing rear silencer heat shield 6838
D4B8072DF21 Wheels and Tyres Guide 6840
44 – Wheels, tyres, vehicle geometry 6844
1 General information 6844
2 Version key (D2) 6845
2 1 Version key (D2) type approval number (K): e1*2007/46*1725*00 to e1*2007/46*1725*04 6845
2 2 Version key (D2) type approval number (K): e1*2007/46*1725*05 6846
2 3 Version key (D2) type approval number (K): e1*2007/46*1725*06 6846
2 4 Version key (D2) type approval number (K): e1*2007/46*1725*07 6847
2 5 Version key (D2) from type approval number (K): e1*2007/46*1725*08 6847
2 6 Version key (D2) as of type approval no (K): e1*2007/46*1725*09 and e1*2007/46*1725*10 6848
2 7 Version key (D2) from type approval number (K): e1*2007/46*1725*11 6848
2 8 Version key (D2) as of type approval no (K): e1*2007/46*1725*12 and e1*2007/46*1725*13 6848
2 9 Version key (D2) from type approval number (K): e1*2007/46*1725*14 6849
2 10 Version key (D2) from type approval number (K): e1*2007/46*1725*15 6849
2 11 Version key (D2) from type approval number (K): e1*2007/46*1725*16 6850
2 12 Version key (D2) from type approval number (K): e1*2007/46*1725*17 6850
2 13 Version key (D2) from type approval no (K): e1*2007/46*1725*18 to e1*2007/46*1725*21 6851
2 14 Version key (D2) from type approval no (K): e1*2007/46*1725*22 to e1*2007/46*1725*24 6851
3 Wheels, tyres 6853
3 1 Tightening torque for wheel bolts 6853
4 Wheel and tyre combinations according to NEDC (based on tyre package) 6854
4 1 Type approval no (K): e1*2007/46*1725*00 to e1*2007/46*1725*06 6854
4 2 Changing to other wheel and tyre combinations 6856
4 2 1 Changing to other wheel and tyre combinations – up to type approval number (K): e1*2007/46*1725*04 6856
4 2 2 Changing to other wheel and tyre combinations – from type approval number (K): e1*2007/46*1725*05 6857
5 Wheel and tyre combinations according to WLTP (without tyre package) 6858
5 1 Type approval number (K): e1*2007/46*1725*06 6858
5 2 Type approval no (K): e1*2007/46*1725*07 to e1*2007/46*1725*08 6859
5 3 Type approval number (K): e1*2007/46*1725*09 6861
5 4 Type approval number (K): e1*2007/46*1725*10 6862
5 5 Type approval number (K): e1*2007/46*1725*11 6864
5 6 Type approval number (K): e1*2007/46*1725*12 and e1*2007/46*1725*13 6865
5 7 Type approval number (K): e1*2007/46*1725*14 6866
5 8 Type approval number (K): e1*2007/46*1725*15 6867
5 9 Type approval number (K): e1*2007/46*1725*16 6868
5 10 Type approval number (K): e1*2007/46*1725*17 6869
5 11 Type approval no (K): e1*2007/46*1725*18 to e1*2007/46*1725*19 6870
5 12 Type approval no (K): e1*2007/46*1725*20 to e1*2007/46*1725*24 6871
5 13 Temporary spare wheel 6872
6 Wheel assignment 6873
6 1 Wheel allocation: all variants apart from Arteon R / Arteon Shooting Brake R 6873
6 1 1 7 J x 17 offset 38 6873
6 1 2 7 5 J x 17 offset 40 6874
6 1 3 8 J x 18 offset 40 6874
6 1 4 8 J x 19 offset 40 6876
6 1 5 8 J x 20 offset 40 6877
6 2 Wheel allocation: Arteon R / Arteon Shooting Brake R 6879
6 2 1 8 J x 18 offset 40 6879
6 2 2 8 J x 19 offset 40 6879
6 2 3 8 J x 20 offset 40 6880
7 Recommended summer tyres 6881
7 1 Recommended summer tyres, worldwide according to country-specific approval 6881
8 Recommended all-season tyres 6883
8 1 Recommended all-season tyres, worldwide according to country-specific approval 6883
9 Recommended winter tyres 6884
9 1 Recommended winter tyres, worldwide according to country-specific approval 6884
D4B80577A1A Fuel supply system petrol engines hybrid vehicles 6885
00 – Technical data 6889
1 Safety information 6889
1 1 Safety regulations for working on fuel supply 6889
1 2 Safety precautions when using testers and measuring instruments during a road test 6890
1 3 Safety measures when working on vehicles with a start/stop system 6890
1 4 Safety notes and safety precautions when working on vehicles with a high-voltage system 6890
1 5 Safety precautions when working in the vicinity of high-voltage components 6892
2 Identification 6893
2 1 Engine number/engine data 6893
3 General information 6894
3 1 Rules for cleanliness when working on auxiliary/supplementary heater and fuel system 6894
4 Repair instructions 6895
4 1 Routing and attachment of lines 6895
4 2 General repair notes 6895
20 – Fuel supply system 6896
1 Fuel 6896
1 1 Assembly overview – fuel tank 6896
1 1 1 Assembly overview – fuel tank 6896
1 1 2 Assembly overview – fuel tank attachments 6898
1 2 Removing and installing fuel tank 6901
1 3 Emptying fuel tank 6906
1 3 1 Emptying fuel tank when fuel pump is intact 6906
1 3 2 Emptying fuel tank if it is more than 3/4 full 6910
1 3 3 Emptying fuel tank if it is less than 3/4 full 6912
2 Fuel delivery unit, fuel gauge sender 6914
2 1 Assembly overview – fuel delivery unit/fuel gauge sender 6914
2 2 Removing and installing fuel delivery unit, fuel gauge sender 6916
2 2 1 Removing and installing fuel delivery unit, fuel gauge sender 6916
2 2 2 Removing and installing fuel line for auxiliary/supplementary heater 6920
2 3 Removing and installing fuel gauge sender -G- 6923
2 4 Removing and installing assembly opening cover 6924
3 Plug-in connectors 6926
3 1 Separating plug-in connectors 6926
4 Activated charcoal filter system 6933
4 1 Connection diagram – activated charcoal filter system 6933
4 2 Assembly overview – activated charcoal filter system 6934
4 3 Removing and installing activated charcoal filter 6936
4 4 Checking fuel tank breather 6937
4 5 Assembly overview – fuel tank shut-off valve -N288- 6943
4 6 Removing and installing tank shut-off valve -N288- 6945
5 Accelerator pedal 6946
5 1 Assembly overview – accelerator module 6946
5 2 Removing and installing accelerator pedal module -GX2- 6946
6 Fuel pump 6948
6 1 Checking fuel system pressurisation pump -G6- 6948
6 1 1 Checking fuel pressure in engine compartment 6948
6 1 2 Measuring pressure at fuel delivery unit -GX1- 6951
6 1 3 Checking fuel delivery rate of fuel system pressurisation pump -G6- in engine compartment 6953
6 1 4 Measuring fuel delivery rate at fuel delivery unit -GX1- 6956
6 1 5 Connecting test instrument adapter for voltage measurement at fuel delivery unit 6959
6 1 6 Connecting remote control 6960
6 2 Removing and installing fuel pump control unit -J538- 6962
7 Senders and sensors 6964
7 1 Removing and installing tank pressure sensor -G400- 6964
D4B80609EAF Air conditioning systems with refrigerant R1234yf – General information 6966
00 – Technical data 6972
1 Safety information 6972
1 1 Safety precautions when working on air conditioning systems 6972
1 2 Safety precautions when handling refrigerants 6973
1 3 Safety measures when working on vehicles with a start/stop system 6973
1 4 Safety precautions when using air conditioner service stations 6973
1 5 Safety measures for working on vehicles with high-voltage system 6974
1 6 Safety precautions when working in the vicinity of high-voltage components 6975
1 7 Safety precautions when working on pressure vessels 6975
2 Laws and regulations 6976
2 1 Legal regulations and standards 6976
2 2 Charging refrigerant circuit with different refrigerants 6977
2 3 Occupational health and safety 6978
3 Repair notes 6979
3 1 Rules for cleanliness 6979
3 2 Refrigerant circuit seals 6979
3 3 Refrigerant and refrigerant oil 6980
3 3 1 Important repair notes for refrigerant and refrigerant oil 6980
3 3 2 Refrigerant oil 6981
3 4 Handling pressure vessels 6982
3 5 Handling refrigerants 6983
4 Identification 6985
4 1 Notice for refrigerant circuit 6985
5 Technical data 6986
5 1 Refrigerant capacity 6986
5 2 Refrigerant oil capacities 6986
5 3 Safety data sheets 6986
6 Basic technical and physical properties 6987
6 1 Basics of air conditioning technology 6987
6 1 1 Physical properties of air conditioning system 6987
6 1 2 Pressure and boiling point of refrigerant 6988
6 1 3 Vapour pressure table for refrigerant 6989
6 2 Physical properties 6991
6 2 1 Refrigerant R1234yf 6991
6 2 2 Potential risks with refrigerant R1234yf 6991
6 2 3 Physical and chemical properties of refrigerant R1234yf 6992
6 2 4 Critical point 6992
6 2 5 Environmental aspects of refrigerant R1234yf 6993
6 2 6 Trade names and designations of refrigerant R1234yf 6993
6 2 7 Colour and odour of R1234yf refrigerant 6994
6 2 8 Vapour pressure of R1234yf refrigerant 6994
6 2 9 Physical properties of R1234yf refrigerant 6994
6 2 10 How R1234yf refrigerant reacts to metals and plastics 6994
6 2 11 Critical temperature / critical pressure of R1234yf refrigerant 6995
6 2 12 Water content of R1234yf refrigerant 6995
6 2 13 Flammability / decomposition of R1234yf refrigerant 6995
6 2 14 Charge factor of refrigerant R1234yf 6995
6 2 15 Evidence of leaks in a refrigerant circuit with R1234yf refrigerant 6996
6 2 16 Analysis of refrigerant R1234yf 6996
6 2 17 Returning contaminated R1234yf refrigerant for analysis, processing or disposal 6997
6 3 Product characteristics 6998
6 4 Function and role of air conditioning system 6998
6 4 1 Principle of operation 6998
6 4 2 Comfort 6999
6 4 3 Environmental aspects 6999
6 5 Other reference material 7000
87 – Air conditioning system 7001
1 Refrigerant circuit 7001
1 1 System overview – refrigerant circuit 7001
1 1 1 System overview – refrigerant circuit with expansion valve and receiver 7001
1 1 2 System overview – refrigerant circuit with restrictor and reservoir 7003
1 1 3 System overview – refrigerant circuit with electrically driven air conditioner compressor (with and without battery cooling module) 7004
1 2 General description – components of refrigerant circuit 7007
1 2 1 Layout and function of refrigerant circuit 7007
1 2 2 Mechanical air conditioner compressor 7008
1 2 3 Electrical air conditioner compressor for hybrid vehicles 7011
1 2 4 Condenser 7014
1 2 5 evaporator 7015
1 2 6 Reservoir 7017
1 2 7 Heat exchanger for heat pump mode 7017
1 2 8 Liquid receiver 7018
1 2 9 Restrictor 7018
1 2 10 Receiver 7020
1 2 11 Expansion valve (with and without shut-off valve) 7022
1 2 12 Refrigerant shut-off valves 7024
1 2 13 Refrigerant line with internal heat exchanger 7026
1 2 14 Quick release couplings of refrigerant lines 7027
1 2 15 Seals 7028
1 2 16 Pipes and hoses in refrigerant circuit 7029
1 2 17 High-pressure safety valve 7029
1 2 18 Non-return valves 7031
1 2 19 Quick-release coupling connections in refrigerant circuit 7032
1 2 20 Connections with valve for switches in refrigerant circuit 7036
1 2 21 Pressure senders and switches in refrigerant circuit 7037
1 2 22 Refrigerant pressure and temperature sender 7038
1 2 23 Air conditioner compressor regulating valve -N280- 7041
1 2 24 Refrigerant temperature sender 7042
1 3 Possible complaints 7043
1 3 1 Prerequisites for investigating a complaint 7043
1 3 2 Possible complaints 7043
1 3 3 Odours from heater and air conditioning unit 7045
1 4 Investigating leaks 7047
1 4 1 General information about investigating leaks in the refrigerant circuit 7047
1 4 2 Searching for leaks in refrigerant circuits using an electronic leak detector 7048
1 4 3 Searching for leaks with UV leak detection system 7049
1 4 4 Detecting leaks in a vacuum test using air conditioner service station, or in a pressure test 7055
1 4 5 Detecting leaks in a pressure test (with nitrogen or compressed air) 7056
1 5 Renewing components 7058
1 5 1 General information about renewing components 7058
1 5 2 Renewing leaking or damaged components of empty refrigerant circuit (apart from air conditioner compressor and receiver) 7059
1 5 3 Renewing leaking or damaged components of charged refrigerant circuit (apart from air conditioner compressor and receiver) 7061
1 5 4 Renewing air conditioner compressor with no need to clean refrigerant circuit 7062
1 5 5 Renewing air conditioner compressor due to leaks or internal damage 7065
1 5 6 Renewing desiccant cartridge / receiver after cleaning refrigerant circuit 7066
1 5 7 Renewing receiver with no need to clean refrigerant circuit 7068
1 5 8 Renewing desiccant cartridge / desiccant bag with no need to clean refrigerant circuit 7069
1 6 Cleaning refrigerant circuit 7070
1 6 1 General information about cleaning refrigerant circuit 7070
1 6 2 Preparations for cleaning refrigerant circuit (flushing with R1234yf refrigerant) 7072
1 6 3 Refrigerant circuit cleaning procedure 7076
1 6 4 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with expansion valve and receiver 7076
1 6 5 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with restrictor and receiver (without high-voltage system) 7081
1 6 6 Adapters for setting up flushing circuits 7084
1 6 7 General information about blowing through with compressed air or nitrogen 7097
1 6 8 Blowing through refrigerant circuit with compressed air or nitrogen 7101
1 7 Checking pressures with pressure gauge 7102
1 7 1 Display on pressure gauges 7102
1 7 2 Pressure gauges enable the following test and measurement work 7103
2 Working with air conditioner service station 7106
2 1 Working with air conditioner service station 7107
2 2 Connecting air conditioner service station to refrigerant circuit 7109
2 3 Performing gas analysis of refrigerant 7112
2 4 Purging refrigerant circuit 7115
2 5 Evacuating refrigerant circuit 7118
2 6 Charging refrigerant circuit 7124
2 7 Bringing air conditioning system into service after charging 7127
2 8 Switching off air conditioner service station and separating from refrigerant circuit 7129
2 9 Charging refrigerant in reservoir 7131
2 10 Emptying air conditioner service station 7132
2 11 Cleaning electrical air conditioning compressor 7132
2 12 Cleaning refrigerant circuit 7135
2 13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal 7138
2 13 1 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 011- 7138
2 13 2 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 007- 7139
2 14 Checking pressures 7143
2 14 1 General information on checking pressures in the refrigerant circuit 7143
2 14 2 Pressures and temperatures in refrigerant circuit 7145
2 14 3 Checking pressures in the refrigerant circuit with the ignition switched off 7149
2 14 4 Checking pressures with air conditioning system switched on – vehicles with mechanical air conditioning compressor 7156
2 14 5 Checking pressures with air conditioning system switched on – vehicles with electrical air conditioning compressor 7178
3 Testing equipment and tools 7231
3 1 Tools and materials available from distribution centre or importer 7231
3 2 Tools and materials available commercially 7231
D4B80609EEB 4 cyl direct injection engine (2 0 l 4 V EA 888 gen III BZ turbocharger chain drive) 7233
00 – Technical data 7241
1 Safety information 7241
1 1 Safety regulations for working on fuel supply 7241
1 2 Safety measures when working on vehicles with start/stop system 7241
1 3 Safety precautions when using testers and measuring instruments during a road test 7242
1 4 Safety precautions when working on ignition system 7242
1 5 Safety precautions when working on the cooling system 7242
1 6 Safety precautions when working on exhaust system 7243
2 Identification 7244
2 1 Engine number/engine data 7244
3 Repair notes 7246
3 1 Rules for cleanliness 7246
3 2 Foreign objects in engine 7246
3 3 Contact corrosion 7246
3 4 Routing and attachment of lines 7246
3 5 Fitting radiator and condensers 7247
3 6 Checking vacuum system 7247
10 – Removing and installing engine 7248
1 Removing and installing engine 7248
1 1 Removing engine 7248
1 2 Separating engine and gearbox 7264
1 2 1 Separating engine and gearbox, vehicles with manual gearbox 7264
1 2 2 Separating engine and gearbox, vehicles with 7-speed dual clutch gearbox 7267
1 2 3 Separating engine and gearbox, vehicles with 6-speed dual clutch gearbox 7271
1 3 Securing engine on engine and gearbox support 7274
1 4 Installing engine 7277
2 Assembly mountings 7281
2 1 Assembly overview – assembly mountings 7281
2 2 Removing and installing engine mounting 7283
2 3 Removing and installing gearbox mounting 7284
2 4 Removing and installing pendulum support 7286
2 4 1 Removing and installing pendulum support, Tiguan, Arteon, T-Roc, Passat 7286
2 4 2 Removing and installing pendulum support, Polo 7287
2 5 Supporting engine in installation position 7288
2 5 1 Supporting engine in installation position, Tiguan 7288
2 5 2 Supporting engine in installation position, Arteon 7292
2 5 3 Supporting engine in installation position, Passat 7295
2 5 4 Supporting engine in installation position, T-Roc 7300
2 5 5 Supporting engine in installation position, Polo 7305
2 6 Checking adjustment of assembly mountings 7309
2 7 Adjusting assembly mountings 7309
3 Engine cover panel 7312
3 1 Removing and installing engine cover 7312
13 – Crankshaft group 7313
1 Cylinder block (pulley end) 7313
1 1 Assembly overview – cylinder block (pulley end) 7313
1 2 Removing and installing poly-V belt 7316
1 3 Removing and installing tensioner for poly V-belt 7317
1 4 Removing and installing vibration damper 7318
1 5 Renewing seal for vibration damper 7325
1 6 Removing and installing bracket for ancillaries 7328
1 7 Removing and installing engine support 7330
2 Cylinder block, gearbox end 7333
2 1 Assembly overview – cylinder block, gearbox end 7333
2 2 Removing and installing flywheel 7334
2 3 Removing and installing sealing flange on gearbox side 7336
3 Crankshaft 7341
3 1 Assembly overview – crankshaft 7341
3 2 Crankshaft dimensions 7344
3 3 Allocation of main bearing shells 7344
3 4 Renewing needle bearing in crankshaft 7346
3 5 Measuring axial clearance of crankshaft 7348
3 6 Measuring radial clearance of crankshaft 7349
3 7 Removing and installing sender wheel 7350
4 Balancer shaft 7352
4 1 Assembly overview – balance shaft 7352
4 2 Removing and installing balance shaft 7354
4 2 1 Removing and installing inlet side balance shaft 7354
4 2 2 Removing and installing exhaust side balance shaft 7357
4 2 3 Renewing oil seal for balance shaft (inlet side) 7359
5 Pistons and conrods 7361
5 1 Assembly overview – pistons and conrods 7361
5 2 Removing and installing pistons 7365
5 3 Checking pistons and cylinder bores 7367
5 4 Separating new conrod 7369
5 5 Checking radial clearance of conrods 7369
5 6 Removing and installing oil spray jets 7370
15 – Cylinder head, valve gear 7372
1 Cylinder head 7372
1 1 Assembly overview – cylinder head 7372
1 2 Removing and installing cylinder head 7375
1 3 Assembly overview – vacuum pump 7381
1 4 Removing and installing vacuum pump 7382
1 5 Checking compression 7384
2 Cover for timing chain 7387
2 1 Assembly overview – cover for timing chain 7387
2 2 Removing and installing timing chain cover 7390
2 2 1 Removing and installing upper timing chain cover 7390
2 2 2 Removing and installing timing chain cover (bottom) 7392
3 Chain drive 7397
3 1 Assembly overview – camshaft timing chains 7397
3 2 Assembly overview – drive chain for balance shaft 7400
3 3 Removing and installing camshaft timing chain 7402
3 4 Removing and installing drive chain for balance shaft 7415
3 5 Checking timing chain 7418
4 Valve gear 7420
4 1 Assembly overview – valve gear 7420
4 2 Removing and installing camshaft 7424
4 3 Removing and installing actuators for camshaft adjustment 7435
4 4 Removing and installing camshaft control valve 1 -N205- 7437
4 5 Removing and installing exhaust camshaft control valve 1 -N318- 7437
4 6 Removing and installing valve stem oil seals 7438
4 6 1 Removing and installing valve stem seals (cylinder head installed) 7438
4 6 2 Removing and installing valve stem seals (cylinder head removed) 7443
5 Inlet and exhaust valves 7449
5 1 Checking valve guides 7449
5 2 Checking valves 7450
5 3 Valve dimensions 7450
17 – Lubrication 7451
1 Sump, oil pump 7451
1 1 Assembly overview – sump/oil pump 7451
1 2 Engine oil: 7454
1 3 Removing and installing lower part of sump 7454
1 3 1 Removing and installing bottom section of sump, plastic sump 7454
1 3 2 Removing and installing bottom section of sump, sheet-metal sump 7456
1 4 Removing and installing upper part of sump 7460
1 5 Removing and installing oil pump 7466
1 6 Removing and installing oil level and oil temperature sender -G266- 7469
2 Engine oil cooler 7471
2 1 Assembly overview – engine oil cooler 7471
2 2 Removing and installing engine oil cooler 7471
3 Crankcase ventilation 7474
3 1 Assembly overview – crankcase breather system 7474
3 2 Removing and installing oil separator 7475
4 Oil filter, oil pressure switch 7477
4 1 Assembly overview – oil filter 7477
4 2 Assembly overview – oil pressure switches/oil pressure control 7477
4 3 Removing and installing piston cooling jet control valve -N522- 7479
4 4 Removing and installing oil pressure switch 7480
4 4 1 Removing and installing oil pressure switch -F1- 7480
4 4 2 Removing and installing oil pressure switch for reduced oil pressure -F378- 7481
4 4 3 Removing and installing stage 3 oil pressure switch -F447- 7482
4 5 Checking oil pressure 7484
4 5 1 Checking engine oil pressure 7484
4 5 2 Checking oil pressure and oil spray jets 7486
4 6 Removing and installing oil pressure regulating valve -N428- 7488
19 – Cooling 7490
1 Cooling system/coolant 7490
1 1 Connection diagram – coolant hoses 7490
1 1 1 Vehicles with manual gearbox 7490
1 1 2 Vehicles with dual clutch gearbox 7491
1 2 Checking cooling system for leaks 7492
1 3 Draining and adding coolant 7496
1 4 Flushing cooling system 7504
1 4 1 Flushing cooling system 7504
1 4 2 Flushing cooling system, quick reference guide 7526
2 Coolant pump, regulation of cooling system 7528
2 1 Assembly overview – coolant pump, thermostat 7528
2 2 Assembly overview – electric coolant pump 7530
2 3 Assembly overview – coolant temperature sender 7533
2 4 Removing and installing electric coolant pump 7534
2 4 1 Removing and installing auxiliary pump for heating -V488- 7534
2 5 Removing and installing coolant pump 7537
2 6 Removing and installing toothed belt for coolant pump 7540
2 7 Removing and installing coolant valves 7541
2 7 1 Removing and installing coolant shut-off valve -N82- 7541
2 7 2 Removing and installing coolant valve for gearbox -N488-, vehicles with 6-speed dual clutch gearbox 7543
2 7 3 Removing and installing coolant valve for gearbox -N488-, vehicles with 7-speed dual clutch gearbox 7545
2 8 Removing and installing actuator for engine temperature regulation -N493- 7546
2 9 Removing and installing coolant temperature sender -G62- 7549
2 10 Removing and installing radiator outlet coolant temperature sender -G83- 7550
3 Coolant pipes 7552
3 1 Assembly overview – coolant pipes 7552
3 2 Removing and installing coolant pipes 7552
3 2 1 Removing and installing front coolant pipe 7552
3 3 Removing and installing upper coolant pipes 7554
4 Radiator, radiator fan 7556
4 1 Assembly overview – radiator 7556
4 1 1 Assembly overview – radiator, Tiguan, Arteon, T-Roc, Passat 7556
4 1 2 Assembly overview – radiator, Polo 7558
4 2 Assembly overview – radiator cowl and radiator fan 7560
4 2 1 Assembly overview – radiator cowl and radiator fan, twin fan 7560
4 2 2 Assembly overview – radiator cowl and radiator fan, single fan 7561
4 3 Removing and installing radiator 7562
4 3 1 Removing and installing radiator, Tiguan, Arteon, T-Roc, Passat 7562
4 3 2 Removing and installing radiator, Polo 7564
4 4 Removing and installing radiator cowl 7569
4 4 1 Removing and installing radiator cowl, twin fan 7569
4 4 2 Removing and installing radiator cowl, single fan 7571
4 4 3 Removing and installing radiator cowl, Polo 7572
4 5 Removing and installing radiator fan 7575
4 5 1 Removing and installing radiator fan, twin fan 7575
4 5 2 Removing and installing radiator fan, single fan 7576
21 – Turbocharging/supercharging 7578
1 Turbocharger 7578
1 1 Assembly overview – turbocharger 7578
1 2 Removing and installing turbocharger 7582
2 Charge air system 7588
2 1 Assembly overview – charge air system 7588
2 1 1 Assembly overview – charge air system, Tiguan, Arteon, T-Roc, Passat 7588
2 1 2 Assembly overview – charge air system, Polo 7589
2 2 Assembly overview – charge-air hose connections 7591
2 3 Removing and installing charge air cooler 7591
2 3 1 Removing and installing charge air cooler, Tiguan, Arteon, T-Roc, Passat 7591
2 3 2 Removing and installing charge air cooler, Polo 7595
2 4 Removing and installing charge pressure sender -G31- 7596
2 5 Checking charge air system for leaks 7597
2 6 Removing and installing air intake pipe between turbocharger and charge air cooler 7599
24 – Mixture preparation – injection 7601
1 Injection system 7601
1 1 Overview of fitting locations – injection system 7601
2 Injectors 7613
2 1 Assembly overview – fuel rail with injectors 7613
2 1 1 Assembly overview – fuel rail with injectors, direct injection 7613
2 1 2 Assembly overview – fuel rail with injectors, indirect injection 7614
2 2 Removing and installing fuel rail 7615
2 3 Removing and installing injectors 7616
2 3 1 Removing and installing injectors, direct injection 7616
2 3 2 Removing and installing injectors, indirect injection 7621
2 4 Renewing seals on injectors 7623
2 5 Cleaning injectors 7626
3 Air filter 7628
3 1 Assembly overview – air filter housing 7628
3 1 1 Assembly overview – air filter housing, Tiguan, Arteon, T-Roc, Passat 7628
3 1 2 Assembly overview – air filter housing, Polo 7630
3 2 Removing and installing air filter housing 7631
3 3 Removing and installing air guide on lock carrier 7633
3 3 1 Removing air duct on lock carrier, Tiguan, Arteon, Passat 7633
3 3 2 Removing air guide on lock carrier, T-Roc 7634
3 3 3 Removing air guide on lock carrier, Polo 7635
4 Intake manifold 7636
4 1 Assembly overview – intake manifold 7636
4 2 Removing and installing intake manifold 7638
4 3 Removing and installing throttle valve module -GX3- 7643
4 4 Cleaning throttle valve module -GX3- 7646
4 5 Checking intake manifold change-over 7647
5 Senders and sensors 7649
5 1 Removing and installing fuel pressure sender -G247- 7649
5 2 Checking fuel pressure sender -G247- 7652
5 3 Removing and installing fuel pressure sender for low-pressure -G410- 7654
5 4 Removing and installing intake manifold sender -GX9- 7655
5 5 Removing and installing air mass meter -G70- 7656
5 6 Assembly overview – actuator for structure-borne sound and control unit for structure-borne sound, Polo 7658
5 7 Removing and installing pressure differential sender for particulate filter -G1037- 7660
6 Engine/motor control unit 7662
6 1 Removing and installing engine control unit -J623- 7662
6 2 Removing and installing engine (motor) control unit -J623- with protective housing 7663
7 High-pressure pump 7667
7 1 Assembly overview – high-pressure pump 7667
7 2 Removing and installing high-pressure pump 7669
7 3 Removing and installing high-pressure pipe 7672
8 Lambda probe 7676
8 1 Assembly overview – Lambda probe 7676
8 2 Removing and installing lambda probe 7677
8 2 1 Removing and installing Lambda probe 1 before catalytic converter -GX10- 7677
8 2 2 Removing and installing Lambda probe 1 after catalytic converter -GX7- 7679
26 – Exhaust system 7681
1 Exhaust pipes and silencers 7681
1 1 Assembly overview – silencers 7681
1 1 1 Assembly overview – silencers, Tiguan 7681
1 1 2 Assembly overview – silencer, Arteon, Passat 7682
1 1 3 Assembly overview – silencers, Polo 7683
1 1 4 Assembly overview – silencers, T-Roc 7685
1 2 Removing and installing silencer 7686
1 2 1 Removing and installing silencer, Tiguan 7686
1 2 2 Removing and installing silencer, Arteon, Passat 7688
1 2 3 Removing and installing front silencer, Polo 7689
1 2 4 Removing and installing rear silencer, Polo 7690
1 2 5 Removing and installing silencers, T-Roc 7691
1 3 Separating exhaust pipes from silencers 7693
1 3 1 Separating exhaust pipes/silencers, Arteon, Passat 7693
1 3 2 Separating exhaust pipes/silencers, Polo 7696
1 3 3 Separating exhaust pipes/silencers, T-Roc 7697
1 4 Aligning exhaust system free of stress 7699
1 5 Checking exhaust system for leaks 7699
2 Emission control 7700
2 1 Assembly overview – emission control 7700
2 1 1 Assembly overview – exhaust gas treatment, Tiguan 7700
2 1 2 Assembly overview – emission control, Arteon, Polo, T-Roc, Passat 7704
2 1 3 Assembly overview – emission control, vehicles with particulate filter and front-wheel drive 7705
2 1 4 Assembly overview – emission control, vehicles with particulate filter and all-wheel drive 7707
2 1 5 Catalytic converter – specified torque and tightening sequence 7709
2 2 Assembly overview – bracket and pipes for pressure differential sender for particulate filter -G1037- 7710
2 3 Removing and installing catalytic converter 7711
2 3 1 Removing and installing catalytic converter, vehicles without particulate filter and front-wheel drive 7711
2 3 2 Removing and installing catalytic converter, vehicles without particulate filter and all-wheel drive 7715
2 3 3 Removing and installing catalytic converter, vehicles with particulate filter and front-wheel drive 7722
2 3 4 Removing and installing catalytic converter, vehicles with particulate filter and all-wheel drive 7726
2 4 Removing and installing holder of pressure differential sender for particulate filter -G1037- 7731
3 Exhaust gas temperature regulation 7732
3 1 Assembly overview – exhaust gas temperature regulation 7732
3 2 Removing and installing parts of exhaust gas temperature regulation 7733
3 2 1 Removing and installing exhaust gas temperature sender, vehicles with front-wheel drive 7733
3 2 2 Removing and installing exhaust gas temperature sender, vehicles with all-wheel drive 7735
28 – Ignition system 7738
1 Ignition system 7738
1 1 Assembly overview – ignition system 7738
1 2 Removing and installing ignition coils with output stage 7740
1 3 Removing and installing knock sensor 1 -G61- 7742
1 4 Removing and installing Hall sender 7743
1 4 1 Removing and installing Hall sender -G40- 7743
1 4 2 Removing and installing Hall sender 3 -G300- 7744
1 5 Removing and installing engine speed sender -G28- 7744
D4B80729B8D 7 speed dual clutch gearbox 0GC 7747
00 – Technical data 7751
1 Safety information 7751
1 1 General safety provisions 7751
1 2 Safety measures when working on vehicles with a start/stop system 7752
1 3 Notes on tow-starting/towing 7752
1 4 Safety precautions when using testers and measuring instruments during a road test 7752
2 Identification 7754
2 1 Gearbox identification 7754
3 Repair instructions 7756
3 1 General information 7756
3 2 Rules for cleanliness 7757
3 3 General repair instructions 7757
3 4 Gaskets and seals 7759
3 5 Nuts and bolts 7759
4 Technical data 7761
4 1 Allocation gearbox – engine 7761
4 1 1 Arteon 2017 ► 7761
4 1 2 Passat 2015 ►, Passat Estate 2015 ► 7761
4 1 3 Passat 2019 ►, Passat Estate 2019 ► 7761
4 2 Capacities 7761
5 Electrical components 7763
5 1 Overview of fitting locations – electrical components 7763
30 – Clutch 7764
1 Clutch 7764
1 1 Assembly overview – dual clutch 7764
1 2 Removing and installing clutch end cover 7765
1 3 Removing dual clutch 7770
1 4 Installing dual clutch 7773
34 – Controls, housing 7783
1 Mechatronic unit 7783
1 1 Assembly overview – mechatronic unit 7783
1 2 Removing and installing sump 7784
1 3 Removing and installing mechatronic unit 7787
2 Bevel box 7791
2 1 Assembly overview – bevel box 7791
2 2 Distinguishing between different types of bevel boxes 7792
2 3 Removing and installing bevel box 7793
2 3 1 Removing bevel box 7793
2 3 2 Installing bevel box 7799
3 Selector mechanism 7804
3 1 Assembly overview – selector mechanism 7804
3 2 Manual release from position P 7806
3 3 Removing and installing selector lever handle 7806
3 4 Moving push-button in the handle to installation position 7810
3 5 Removing and installing selector mechanism 7812
3 5 1 Removing and installing selector mechanism with selector lever cable 7812
3 5 2 Removing and installing selector mechanism without selector lever cable 7814
3 6 Removing and installing gear selector cable 7817
3 7 Checking selector mechanism 7819
3 8 Checking and adjusting selector lever cable 7820
3 9 Renewing selector shaft seal 7823
4 Removing and installing gearbox 7826
4 1 Specified torques for gearbox 7826
4 1 1 Gearbox carrier to engine and bevel box 7826
4 2 Removing gearbox 7828
4 2 1 Removing gearbox, Arteon 2017 ►, vehicles with 2 0 l petrol engine, front-wheel drive 7828
4 2 2 Removing gearbox, Arteon 2017 ►, vehicles with petrol engine, all-wheel drive 7835
4 2 3 Removing gearbox, Arteon 2017 ►, vehicles with diesel engine, front-wheel drive 7844
4 2 4 Removing gearbox, Passat 2015 ►, Passat estate 2015 ►, Passat 2019 ►, Passat estate 2019 ►, vehicles with diesel engine, front-wheel drive 7851
4 2 5 Removing gearbox, Passat 2015 ►, Passat estate 2015 ►, Passat 2019 ►, Passat estate 2019 ►, vehicles with diesel engine, all-wheel drive 7860
4 2 6 Removing gearbox, Arteon 2017 ►, vehicles with diesel engine, all-wheel drive 7870
4 2 7 Removing gearbox, Passat 2015 ►, Passat estate 2015 ►, Passat 2019 ►, Passat estate 2019 ►, vehicles with petrol engine, front-wheel drive 7882
4 2 8 Removing gearbox, Arteon 2017 ►, vehicles with 1 5 l petrol engine, front-wheel drive 7891
4 2 9 Removing gearbox, Passat 2015 ►, Passat estate 2015 ►, Passat 2019 ►, Passat estate 2019 ►, vehicles with petrol engine, all-wheel drive 7899
4 3 Installing gearbox 7910
5 Assembly mountings 7912
5 1 Assembly overview – assembly mountings 7912
6 Transporting gearbox 7915
7 Securing to engine and gearbox support 7917
8 Gear oil circuit 7919
8 1 Assembly overview – gear oil circuit 7919
8 2 Removing and installing gear oil cooler 7919
8 3 Removing and installing gear oil filter 7922
8 4 Removing and installing motor for auxiliary hydraulic pump 1 for gearbox oil -V475- 7924
9 Gear oil 7927
9 1 Overview of oil drain and inspection plugs 7927
9 2 Tools for gear oil change 7927
9 3 Checking gear oil level 7929
9 4 Draining and filling gear oil 7933
35 – Gears, shafts 7937
1 Currently, no repairs can be made to gears and shafts 7937
39 – Final drive – differential 7938
1 Gear oil 7938
1 1 Checking gear oil level 7938
1 1 1 Checking gear oil level, bevel box “0CN” 7938
1 1 2 Checking gear oil level, bevel box “0FN” 7939
1 2 Draining and filling gear oil 7940
1 2 1 Draining and filling gear oil, bevel box “0CN” 7940
1 2 2 Draining and filling gear oil, bevel box “0FN” 7943
2 Oil seals 7947
2 1 Overview of fitting locations – oil seals 7947
2 2 Renewing left seal 7947
2 2 1 Renewing oil seal for left flange shaft 7947
2 3 Renewing right seal 7951
2 3 1 Renewing seal on right of gearbox, front-wheel drive vehicles 7951
2 3 2 Renewing seal on right of gearbox, vehicles with all wheel drive 7953
3 Differential 7955
3 1 Removing and installing right flange shaft 7955
3 1 1 Removing and installing flange shaft – vehicles with all-wheel drive 7955
4 Components of bevel box 7958
4 1 Assembly overview – components of bevel box 7958
4 1 1 Assembly overview – components of bevel box, 0CN 7958
4 1 2 Assembly overview – components of bevel box, 0FN 7960
4 2 Renewing bevel box seals 7962
4 3 Renewing seal on right of bevel box 7962
4 4 Renewing left seal 7963
4 5 Renewing needle bearing for right flange shaft 7965
4 6 Removing and installing output flange 7967
4 6 1 Removing and installing output flange, 0CN 7967
4 6 2 Removing and installing output flange, 0FN 7977
D4B802605A6 General information Paint passenger vehicles 7983
00 – Technical data 7989
1 Safety information 7989
1 1 Safety precautions when painting natural gas-powered vehicles 7989
1 2 Safety precautions when painting electric drive vehicles 7990
2 General information 7991
2 1 Paintwork structure of a factory finish 7991
2 2 Paint structure of service department finish 7994
2 2 1 Paintwork structure, base coat 7994
2 2 2 Paintwork structure, metallic effect 7997
2 3 Fundamental approach to dealing with areas sanded through to the substrate (bare metal surface) 7999
2 4 Reduced paint structure in engine compartment and inside of bonnet 7999
2 5 Instructions for work on underbody and stone chip protection 7999
2 6 Work instruction for window flange area 8001
2 7 Pre-treatment of bonded surfaces when renewing laser-welded roofs 8003
2 8 Corrosion protection measures for wing surface in contact with wheel housing liner 8007
2 9 Notes on treating corroded fold areas 8008
2 10 Corrosion protection for body components, add-on components and welded components 8010
2 11 Painting parking aid sensor 8011
2 12 ACC – Adaptive Cruise Control 8013
2 13 Instructions for painting bumper cover in area of lane change assist control unit 8013
3 Genuine products 8015
3 1 Paint products in customer service 8015
3 2 General application instructions for repair and painting systems 8016
3 2 1 Aqua Premium – application instructions for water-based products 8016
3 2 2 Setting gloss level of HS clear coats and HS top coats with matting additive 8019
3 2 3 Setting gloss level of 2-pack HS clear coats with 2-pack clear coat, matt 8029
3 2 4 Repair paintwork system for matt-finished vehicles 8031
3 2 5 Paintwork system for plastic components 8036
3 2 6 Aqua Premium system, blending system for 2-stage colours 8044
3 2 7 Aqua Premium system, blending system for 3-stage colours 8053
3 2 8 Aqua Premium system, product preparation for processing 8060
3 2 9 Aquaplus design and multi-colour painting 8067
3 2 10 Processing instructions for paint with limited hiding power 8072
3 3 Filler 8072
3 3 1 2-pack steel filler set 8072
3 3 2 2-pack fine filler 8076
3 3 3 2-pack fine filler, flexible 8080
3 3 4 2-pack spray filler 8083
3 3 5 2-pack IR premium filler 8089
3 3 6 2-pack epoxy resin filler 8094
3 4 Priming metal 8098
3 4 1 1-pack anti-corrosion wash primer 8098
3 4 2 1-pack wash primer 8103
3 4 3 2-pack wash primer 8108
3 5 Priming plastic materials 8114
3 5 1 Adhesion promoter (transparent) 8114
3 6 Surfacer 8118
3 6 1 2-pack HS Vario surfacer 8118
3 6 2 2-pack HS premium surfacer 8128
3 6 3 2-pack HS Performance surfacer 8137
3 6 4 2-pack primer surfacer for plastics 8146
3 6 5 2-pack HS wet-on-wet surfacer 8152
3 6 6 2-pack base filler, professional 8162
3 7 Top coats 8179
3 7 1 2-pack HS top coat 8179
3 7 2 Aquaplus system, uni (solid-colour) and metallic colours 8188
3 7 3 Aquaplus system (pearlescent and heliochrome) 8196
3 7 4 Aquaplus blending system 8204
3 7 5 Aqua Premium system 8210
3 7 6 Aqua Premium blending system 8223
3 7 7 Aqua Premium system (painting rims) 8230
3 8 Clear coats 8239
3 8 1 2-pack HS clear coat 8239
3 8 2 2-pack MS matt clear coat 8246
3 8 3 2-pack HS Vario clear coat 8252
3 8 4 2-pack HS optimum clear coat 8260
3 8 5 2-pack HS optimum plus clear coat 8266
3 8 6 2-pack HS brilliant clear coat 8271
3 8 7 2-pack HS brilliant plus clear coat 8276
3 8 8 2-pack HS Performance clear coat 8282
3 8 9 Blender 8288
3 9 Hardener 8293
3 9 1 2-pack HS hardener 8293
3 9 2 2-pack VHS hardeners and 2-pack VHS Performance hardeners 8297
3 9 3 Hardener for 2-pack primer surfacer 8301
3 9 4 Aqua Premium hardener 8301
3 10 Thinners 8302
3 10 1 2-pack thinner 8302
3 10 2 HS spot thinner 8305
3 10 3 Demineralised water 8307
3 11 Anti-corrosion materials 8308
3 11 1 Anti-corrosion wax 8308
3 11 2 Cavity sealant 8309
3 11 3 Anti-corrosion wax (in aerosol can) 8312
3 12 Underseal 8313
3 12 1 Permanent underseal -D 314 D36 M2-, grey 8313
3 12 2 Permanent underseal -D 314 D37 M2-, black 8316
3 12 3 Permanent underseal -D 314 D38 M2-, light 8319
3 12 4 Underseal -D 314 D39 A3-, black 8322
3 13 Stone deflector 8324
3 13 1 Stone chip guard -AKR 311 KD1 05- 8324
3 13 2 Stone chip guard -AKR 311 KD1 10- 8326
3 14 Wax-based underseal 8333
3 14 1 Wax-based underseal -D 316 D38 A2- 8333
3 14 2 Wax-based underseal -D 316 000 A1- 8335
3 14 3 Spray wax -D 322 100 M2- 8337
3 15 Sealing materials 8338
3 15 1 Polyurethane adhesive sealant (bonding compound) 8338
3 15 2 Sprayable sealant 8341
3 15 3 Adhesive sealant 8344
3 16 Cleaning agents 8346
3 16 1 Silicone remover 8346
3 16 2 Cleaner for plastics 8348
3 16 3 Cleaner for plastics, anti-static 8349
3 16 4 Industrial dirt remover 8349
3 17 SprayMax system 8351
3 17 1 1-pack anti-corrosion primer 8351
3 17 2 1-pack test paint 8355
3 17 3 1-pack clear coat 8358
3 17 4 1-pack wash primer 8361
3 17 5 1-pack Fill Clean spray can -LLS MAX 099-/1-pack Fill Clean spray can -LLS MAX 100- – Aquaplus system 8366
3 17 6 1-pack fill clean spray can -LLS MAX 112-, Aqua Premium system 8373
3 17 7 2-pack surfacer 8381
3 17 8 2-pack HS Performance surfacer 8388
3 17 9 2-pack clear coat 8396
3 17 10 2-pack epoxy primer surfacer 8401
3 17 11 2-pack wash primer 8407
3 17 12 Silicone remover -LLS MAX 007- 8413
3 17 13 Slow-drying silicone remover -LLS MAX 008- 8415
3 17 14 Blender 8418
3 17 15 Adhesion promoter 8420
3 18 Additional materials 8424
3 18 1 Matting additive -ALN 775 106- 8424
3 18 2 Matting additive -LVM 769 810 A2- 8431
3 18 3 Texture additive 8434
3 18 4 Blending additive for Aquaplus 8440
3 18 5 Additive for Aqua Premium 8441
4 Workshop equipment 8442
4 1 Tools 8442
4 1 1 Spray can filling device -VAS 6425- 8442
4 1 2 Paint thickness tester -VAS 6272- 8443
4 1 3 Paint thickness tester -VAS 6197- 8444
4 1 4 Paint thickness tester -VAS 5278- 8444
4 1 5 Stone chip tester -VAS 5102A- 8445
4 1 6 Pneumatic brush grinder set -VAS 6446- 8446
4 1 7 Brush grinder set -VAS 6776- 8446
4 1 8 Suction feed spray-gun -V A G 1538- 8448
4 1 9 Infrared heater -VAS 6873- 8449
4 1 10 Stand -VAS 6873/1- 8449
4 1 11 Infrared heater -VAS 6874- 8450
4 1 12 Infrared heater -VAS 6875- 8451
4 1 13 Infrared heater -VAS 6876- 8451
4 1 14 Infrared heater -VAS 6877- 8452
4 1 15 Infrared heater -VAS 6878- 8453
4 1 16 Infrared heater -VAS 6879- 8454
4 2 Tack cloths 8454
4 2 1 Tack cloth -VAS 6177- 8454
4 2 2 Buffing cloth, white -VAS 6176- 8455
D4B802791F3 6 speed dual clutch gearbox 0D9 8456
00 – Technical data 8460
1 Safety information 8460
1 1 General safety provisions 8460
1 2 Safety measures when working on vehicles with a start/stop system 8460
1 3 Safety precautions when using testers and measuring instruments during a road test 8461
2 Identification 8462
2 1 Gearbox identification 8462
2 1 1 Identification on gearbox 8462
2 1 2 Reading gearbox code letters 8462
3 Repair notes 8465
3 1 General repair instructions 8465
3 1 1 General information 8465
3 2 Gaskets, seals 8466
3 3 Nuts and bolts 8466
4 Technical data 8468
4 1 Capacities 8468
4 1 1 Capacities – dual clutch gearbox 8468
4 1 2 Capacities, front differential lock 8468
4 1 3 Bevel box 8468
5 Electrical components 8469
5 1 Overview of fitting locations – electrical components 8469
5 1 1 Overview of fitting locations – gearbox control 8469
5 1 2 Overview of fitting locations – electrical components, front differential lock 8469
30 – Clutch 8471
1 Clutch 8471
1 1 Assembly overview – dual clutch 8471
1 2 Removing and installing clutch end cover 8473
1 3 Removing dual clutch 8478
1 4 Installing dual clutch 8479
34 – Controls, housing 8488
1 Mechatronic unit 8488
1 1 Assembly overview – mechatronic unit 8488
1 1 1 Renewing securing clip on vehicle connector 8491
1 2 Removing and installing oil pan 8493
1 3 Removing and installing mechatronic unit for dual clutch gearbox -J743- 8501
1 3 1 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox installed 8501
1 3 2 Removing and installing mechatronic unit for dual clutch gearbox -J743-, gearbox removed 8515
2 Bevel box 8523
2 1 Assembly overview – bevel box 8523
2 2 Removing bevel box 8524
2 3 Installing bevel box 8531
3 Selector mechanism 8535
3 1 Assembly overview – selector mechanism 8535
3 1 1 Assembly overview – selector mechanism, manufacturer ZF 8535
3 1 2 Assembly overview – selector mechanism, manufacturer ECS 8536
3 2 Manual release from position P 8538
3 2 1 Emergency release from P position, manufacturer ZF 8538
3 2 2 Emergency release from P position, manufacturer ECS 8540
3 3 Removing and installing selector lever handle 8542
3 3 1 Removing and installing selector lever handle, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ►, T-Roc, T-Roc Cabriolet 8542
3 3 2 Removing and installing selector lever handle, Passat 2015 ►, Passat estate 2015 ►, Arteon 2018 ►, Passat estate 2019 ► 8546
3 3 3 Removing and installing selector lever handle, Polo 2018 ►, Golf SV 2015 ►, Golf SV 2018 ► 8550
3 3 4 Removing and installing selector lever handle, Touran 2016 ► 8553
3 3 5 Removing and installing selector lever handle, Tiguan 2016 ► 8557
3 4 Bringing interlock button in handle into installation position 8561
3 5 Removing and installing selector mechanism 8563
3 5 1 Removing and installing selector mechanism with selector lever cable 8563
3 5 2 Removing and installing selector mechanism without selector lever cable, manufacturer ZF 8566
3 5 3 Removing and installing selector mechanism without selector lever cable, manufacturer ECS 8569
3 6 Adjusting selector mechanism 8572
3 7 Removing and installing gear selector cable 8578
3 7 1 Removing and installing selector lever cable, manufacturer ZF 8578
3 7 2 Removing and installing selector lever cable, manufacturer ECS 8581
3 8 Checking selector mechanism 8584
3 9 Checking and adjusting selector lever cable 8585
3 10 Renewing selector shaft seal 8587
4 Removing and installing gearbox 8590
4 1 Removing gearbox 8590
4 1 1 Removing gearbox, Golf 2013 ►, Golf Estate 2014 ►, Golf 2017 ►, Golf Estate 2017 ►, vehicles with diesel engine 8590
4 1 2 Removing gearbox, Golf SV 2015 ►, Golf SV 2018 ►, T-Roc, T-Roc Cabriolet, vehicles with diesel engine 8598
4 1 3 Removing gearbox, Golf 2013 ►, Golf 2017 ►, vehicles with petrol engine 8607
4 1 4 Removing gearbox, Golf Estate 2014 ►, Golf Estate 2017 ►, vehicles with diesel engine, all-wheel drive 8615
4 1 5 Removing gearbox, Golf Estate 2014 ►, Golf Estate 2017 ►, vehicles with petrol engine, all-wheel drive 8626
4 1 6 Removing gearbox, Passat 2015 ►, Passat Variant 2015 ►, Arteon 2018 ►, vehicles with diesel engine, front-wheel drive, radiator version “1” or “3” 8634
4 1 7 Removing gearbox, Passat 2015 ►, Passat Variant 2015 ►, Arteon 2018 ►, vehicles with diesel engine, front-wheel drive, radiator version “2” 8642
4 1 8 Removing gearbox, Passat 2015 ►, vehicles with diesel engine, all-wheel drive 8652
4 1 9 Removing gearbox, Passat 2015 ►, Passat estate 2015 ►, Passat 2019 ►, vehicles with petrol engine 8663
4 1 10 Removing gearbox, Passat 2015 ►, Passat estate 2015 ►, Passat estate 2019 ►, vehicles with petrol engine, all-wheel drive 8671
4 1 11 Removing gearbox, Touran 2016 ►, vehicles with diesel engine 8681
4 1 12 Removing gearbox, Tiguan 2016 ►, vehicles with 1 4 l petrol engine 8688
4 1 13 Removing gearbox, Polo 2018 ►, Polo 2022 ►, vehicles with 2 0 l petrol engine 8700
4 2 Gearbox transport 8710
4 3 Installing gearbox 8711
4 4 Specified torques for gearbox 8717
5 Assembly mountings 8720
5 1 Assembly overview – assembly mountings 8720
6 Dismantling and assembling gearbox 8724
6 1 Assembly overview – gearbox 8724
7 Securing to engine and gearbox support 8728
7 1 Secure gearbox on engine and gearbox support 8728
7 2 Secure front differential lock to engine and gearbox support 8729
8 Gear oil circuit 8731
8 1 Removing and installing gear oil cooler 8731
8 2 Removing and installing cover for gear oil pump 8734
8 3 Removing and installing gear oil pump 8736
8 4 Removing and installing gear oil filter 8738
9 Gear oil 8741
9 1 Checking gear oil level 8741
9 2 Draining and filling gear oil 8744
10 Front differential lock 8748
10 1 Assembly overview – front differential lock 8748
10 2 Removing front differential lock 8748
10 2 1 Transporting front differential lock 8752
10 3 Installing front differential lock 8752
10 4 Removing and installing differential lock control unit -J647- 8754
35 – Gears, shafts 8756
1 Currently, no repairs can be made to gears and shafts 8756
39 – Final drive – differential 8757
1 Gear oil 8757
1 1 Checking gear oil level 8757
1 1 1 Checking gear oil in bevel box 8757
1 1 2 Filling gear oil in bevel box 8757
2 Oil for front differential lock 8761
2 1 Checking oil level for front differential lock 8761
2 2 Draining and filling oil for front differential lock 8762
3 Oil seals 8766
3 1 Overview of fitting locations – oil seals 8766
3 2 Renewing left seal 8768
3 3 Renewing right seal 8772
3 3 1 Renewing right oil seal, front wheel drive 8772
3 3 2 Renewing outer seal on right of bevel box 8777
3 3 3 Renewing right seal on gearbox, between front differential lock and gearbox or between bevel box and gearbox 8778
3 3 4 Renewing seal on bevel box between bevel box and gearbox 8780
3 3 5 Renewing oil seal for propshaft drive flange at bevel box 8781
4 Components of front differential lock 8789
4 1 Assembly overview – components of front differential lock 8789
4 2 Checking function 8791
4 3 Removing and installing pump for front differential lock -V181- 8791
4 4 Removing and installing coupling for front differential lock 8793
4 5 Renewing seal for front differential lock 8793
4 5 1 Renewing outer seal on right of front differential lock 8793
4 5 2 Renewing seal between front differential lock and gearbox on front differential lock 8797
4 5 3 Renewing seal for right flange shaft in front differential lock 8799
4 6 Renewing ball bearing for flange shaft 8801
5 Bevel box 8805
5 1 Assembly overview – bevel box 8805
5 2 Removing and installing right flange shaft 8807
5 3 Dismantling and assembling bevel box 8810
5 3 1 Renewing needle bearing (polygon bearing) for right flange shaft 8810
5 3 2 Renewing output flange and redetermining thickness of shim, bevel box removed 8812
D4B8027068B Air conditioning systems with refrigerant R134a General information 8825
00 – Technical data 8831
1 Safety information 8831
1 1 Safety precautions when working on air conditioning systems 8831
1 2 Safety precautions when working on high-voltage system 8832
1 3 Safety precautions when working in the vicinity of high-voltage components 8832
1 4 Safety precautions when tow-starting or towing 8833
2 Repair instructions 8834
2 1 Rules for cleanliness when working on high-voltage system 8834
3 General information on air conditioning 8835
3 1 Other reference material 8835
3 2 Basics of air conditioning technology 8835
3 2 1 Physical principles: 8835
3 2 2 Heat always flows from a warmer to a colder substance 8836
3 2 3 Pressure and boiling point 8836
3 3 Vapour pressure table for refrigerant R134a 8837
3 4 Refrigerant R134a 8838
3 4 1 Physical data of refrigerant R134a 8838
3 4 2 Critical point 8838
3 4 3 Environmental aspects of refrigerant R134a 8839
3 5 Properties of refrigerant R134a 8839
3 5 1 Trade names and designations 8839
3 5 2 Colour 8839
3 5 3 Vapour pressure 8839
3 5 4 Physical properties of R134a 8840
3 5 5 Effects on metal 8840
3 5 6 Critical temperature and critical pressure 8840
3 5 7 Union 8840
3 5 8 Charge factor 8840
3 5 9 Detecting leaks 8840
3 6 Refrigerant oil 8841
3 6 1 Properties of refrigerant oil 8841
3 7 Comfort 8842
3 7 1 Environmental aspects 8842
3 8 How air conditioning works 8843
3 9 General work safety 8843
3 9 1 Product characteristics 8843
3 9 2 Handling refrigerants 8844
3 9 3 Wear safety goggles 8844
3 9 4 Wear protective gloves and apron 8844
3 9 5 Do not allow liquid refrigerant to come in contact with the skin 8844
3 9 6 Do not breath in refrigerant vapour 8844
3 9 7 Absolutely NO SMOKING 8844
3 9 8 Welding and soldering on refrigeration systems 8844
3 9 9 Pungent smell 8845
3 9 10 First aid 8845
3 9 11 Handling pressure vessels 8845
3 9 12 Do not heat up above 50°C 8845
3 9 13 Do not expose to uncontrolled heat 8845
3 9 14 Seal empty tanks/containers 8845
3 9 15 Safety instructions for using extraction and charging equipment 8846
3 10 Safety measures when working on vehicles with air conditioning and when working with refrigerant R134a 8846
3 11 Basics for working on refrigerant circuit 8847
3 11 1 O-ring 8848
3 11 2 Before operating the air conditioning system after recharging with refrigerant 8849
4 General information on refrigerant circuit 8850
4 1 Components of refrigerant circuit 8850
4 1 1 Distribution of the refrigerant circuit components and their influence on the high-pressure and low-pressure sides 8850
4 1 2 Air conditioning system compressor with magnetic clutch: 8850
4 1 3 Air conditioner compressor without magnetic clutch 8851
4 1 4 Air conditioner compressor without magnetic clutch, with elastic drive coupling 8852
4 1 5 Electrical air conditioner compressor for high-voltage system 8853
4 1 6 Condenser 8854
4 1 7 evaporator 8854
4 1 8 Reservoir 8855
4 1 9 Restrictor 8855
4 1 10 Receiver 8856
4 1 11 Expansion valve 8857
4 1 12 O-ring 8858
4 1 13 Pipes and hoses of refrigerant circuit 8858
4 1 14 High-pressure safety valve 8858
4 2 Design of refrigerant circuit 8861
4 2 1 Refrigerant circuit with expansion valve and evaporator 8861
4 2 2 Refrigerant circuit with restrictor and reservoir 8861
4 3 Evacuation and charging valves for quick-release couplings of air conditioner service station on refrigerant circuit 8862
4 3 1 Evacuation and charging valve with Schrader valve 8862
4 3 2 Extraction and charging valve, high-pressure side 8863
4 3 3 Extraction and charging valve, low-pressure side 8864
4 4 Switches and senders in refrigerant circuit and related connections 8864
4 4 1 High-pressure switch for air conditioning system -F23- 8864
4 4 2 High-pressure switch for magnetic clutch -F118- 8865
4 4 3 Low-pressure switch for air conditioning system -F73- 8865
4 4 4 Connections with valve for switches in refrigerant circuit 8866
4 4 5 Air conditioning system pressure switch -F129- 8866
4 4 6 High-pressure sender -G65- 8867
4 4 7 Refrigerant pressure and temperature sender -G395- 8868
4 4 8 Air conditioner compressor regulating valve -N280- 8868
4 5 Electrical components not installed in refrigerant circuit 8869
4 5 1 Control and regulating unit for air conditioning system -J127- 8869
4 5 2 Radiator fan control unit -J293- 8869
4 5 3 Radiator fan control unit -J293- 8870
4 5 4 Temperature switch for evaporator -E33- 8871
4 5 5 Evaporator output temperature sender -G263- or evaporator temperature sensor -G308- 8871
4 6 Pressures and temperatures in refrigerant circuit 8872
4 7 Refrigerant circuit with expansion valve 8872
4 8 Refrigerant circuit with restrictor and reservoir 8874
4 9 Test and measurement work that can be performed using a pressure gauge 8876
4 9 1 Pressure gauges enable the following test and measurement work 8876
4 10 Air conditioner service and recycling equipment 8877
4 10 1 Classification of extraction and charging devices in groups 8877
4 10 2 Charging devices that do not require a permit 8877
4 11 Notes to repairs on refrigerant circuit 8878
5 Laws and regulations 8879
5 1 Laws and regulations 8879
5 2 Recycling and refuse law 8884
5 2 1 Disposal of refrigerant and refrigerant machine oil 8884
5 3 Converting R12 refrigerant circuits to R134a refrigerant circuits and servicing them (retrofitting) 8885
5 4 Maintaining records on refrigerant 8885
6 Refrigerant circuit 8886
6 1 Important repair notes on air conditioning 8886
6 2 Converting refrigerant circuits from R12 refrigerant to R134a 8886
7 Working with the air conditioner service station 8887
7 1 Important instructions for working with the air conditioner service station 8887
7 2 Connecting a air conditioner service station for measuring and testing 8888
7 3 Drain the refrigerant circuit using the air conditioner service station 8889
7 4 Evacuating refrigerant circuit using air conditioner service station 8889
7 5 Filling refrigerant circuit with air conditioner service station 8891
7 6 Bringing air conditioning system into service after charging 8892
7 7 Charging the container in the air conditioning service station with refrigerant 8892
7 8 Emptying air conditioner service station 8893
8 Detecting leaks in refrigerant circuit 8894
8 1 Leak detection in refrigerant circuit using compressed air or nitrogen 8895
8 2 Searching for leaks in refrigerant circuits using leak detector -V A G 1796- 8896
8 3 Detecting leaks in refrigerant circuit using leak detecting system -VAS 6196- or leak detecting system -VAS 6201- or a later model 8897
9 Clearing refrigerant circuit of contaminants 8905
9 1 Vehicles with high-voltage system (hybrid vehicles) 8905
9 2 Blowing through refrigerant circuit with compressed air and nitrogen 8906
9 2 1 Flushing refrigerant circuit 8908
9 3 Flushing refrigerant circuit with refrigerant R134a 8908
9 3 1 Principle circuit diagrams for various purging circuits 8916
9 3 2 Purging electrical air conditioner compressor 8922
9 3 3 Adapters for setting up flushing circuits 8926
10 Clearing refrigerant circuit of contaminants, commercial vehicles 8940
10 1 Vehicles with high-voltage system 8940
10 2 Flushing refrigerant circuit with refrigerant R134a 8941
10 3 Adapters for setting up flushing circuits 8941
10 4 Procedure for setting up and flushing refrigerant circuit, Amarok 2023 ► 8945
10 5 Procedure for setting up and flushing refrigerant circuit, Amarok 2010 ► 8945
10 5 1 Connection diagram for flushing circuit 8945
10 5 2 Procedure for setting up and flushing refrigerant circuit 8946
10 6 Procedure for setting up and flushing refrigerant circuit, Caddy 2004 ► 8951
10 6 1 Connection diagram for flushing circuit 8951
10 6 2 Procedure for setting up and flushing refrigerant circuit 8952
10 7 Procedure for setting up and flushing refrigerant circuit, Crafter ►2017 8958
10 7 1 Connection diagram for flushing circuit, vehicles with one evaporator 8958
10 7 2 Connection diagram for flushing circuit, vehicles with second evaporator 8959
10 7 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 8960
10 7 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 8967
10 8 Procedure for setting up and flushing refrigerant circuit, Crafter 2017 ► or MAN TGE ►, Crafter Grand California ► 8975
10 8 1 Connection diagram for flushing circuit, vehicles with one evaporator 8976
10 8 2 Connection diagram for flushing circuit, vehicles with second evaporator 8977
10 8 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 8978
10 8 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 8983
10 9 Procedure for setting up and flushing refrigerant circuit, Transporter 2016 ►, Transporter 2020 ► 8992
10 9 1 Connection diagram for flushing circuit, vehicles with one evaporator 8992
10 9 2 Connection diagram for flushing circuit, vehicles with second evaporator 8993
10 9 3 Procedure for setting up and flushing refrigerant circuit, vehicles with one evaporator 8994
10 9 4 Procedure for setting up and flushing refrigerant circuit, vehicles with second evaporator 8999
11 Complaints 9008
11 1 Possible complaints about refrigerant circuit 9008
11 1 1 Conditions for testing: 9008
11 1 2 Possible complaints 9008
11 2 Odours from heater and air conditioning unit 9009
11 2 1 Does the odour emanate from the evaporator or heat exchanger? 9009
11 2 2 Ultrasonic air conditioner cleaning unit -VAS 6189A- 9010
11 2 3 Spraying the evaporator with the suction feed spray-gun -V A G 1538- and spray lance 9011
12 Connecting the air conditioning service station 9012
12 1 For vehicles that have connections on both low-pressure and high-pressure sides of refrigerant circuit 9012
12 1 1 Connecting a air conditioner service station for measuring and testing 9012
13 Checking pressures on vehicles 9013
13 1 Checking pressures in the refrigerant circuit (using a air conditioning service station) 9013
13 1 1 Conditions for testing 9013
13 1 2 Checking pressures 9014
13 1 3 Continuation of checking pressures 9016
13 2 Checking systems with a restrictor and collector (with internally regulated air conditioner compressor) 9017
13 2 1 Specifications: 9017
13 3 Checking systems with an expansion valve and reservoir (with internally regulated air conditioner compressor) 9021
13 3 1 Specifications: 9021
13 4 Checking systems with an expansion valve and reservoir (without regulated air conditioner compressor) 9026
13 4 1 Conditions for testing 9026
13 4 2 Check 9026
13 4 3 Specified values 9026
13 5 Checking systems with a restrictor and reservoir and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 9027
13 5 1 Specifications: 9027
13 6 Checking systems with an expansion valve, receiver and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor) 9032
13 6 1 Specifications: 9032
13 7 With expansion valve, receiver and electrical air conditioner compressor 9043
14 Renewing components 9044
14 1 In the event of leaking or damaged components (apart from the air conditioner compressor, receiver or reservoir) 9045
14 1 1 If the refrigerant circuit was completely empty 9045
14 1 2 If there is still refrigerant in the refrigerant circuit 9047
14 2 Renew the air conditioner compressor 9047
14 2 1 Without needing to flush refrigerant circuit of contaminants (cleaning), e g in cases of external damage after an accident 9047
14 2 2 Leaks or internal damage (e g noises or lack of power) 9049
14 3 Replace receiver or reservoir and restrictor 9049
14 3 1 After flushing contaminants from refrigerant circuit, e g due to moisture intrusion (because refrigerant circuit was open for a longer period of time) or due to soiling 9049
14 3 2 Without needing to flush contaminants from refrigerant circuit (e g damage in an accident); no refrigerant has escaped and no moisture or dirt has entered refrigerant circuit 9051
15 Testing equipment and tools 9052
15 1 List of test equipment, tools and materials 9052
15 1 1 Tools and materials available from regional sales centre or importer 9052
15 1 2 Tools and materials commercially available 9053
15 1 3 Tools and materials available from regional sales centre or importer 9054
15 1 4 Tools and materials commercially available 9060
D4B8073105E Body Repairs 9063
00 – Technical data 9069
1 Basic instructions 9069
1 1 Original joint 9069
1 2 Used joining techniques 9069
2 Vehicle identification data 9070
2 1 Vehicle identification number 9070
2 2 Type plate 9071
2 3 Vehicle data sticker 9072
3 Safety information 9074
4 Moulded foam inserts 9075
5 Galvanized body parts, high- and higher-strength and hot-formed body panels 9077
6 Laser welding 9080
7 Gaps/shut lines 9081
7 1 Body – front 9081
7 2 Body, centre 9085
7 3 Body, rear 9088
8 Body dimensions 9091
8 1 Body – front 9091
8 2 Body, centre 9092
8 3 Body, rear 9097
8 4 Floor panel, front 9098
8 5 Floor panel, centre 9099
8 6 Floor panel, rear 9100
9 Straightening bracket set 9102
9 1 Setup overview of complete body 9102
10 Portal gauge 9104
10 1 Setup overview of complete body 9104
50 – Body – front 9106
1 Renewing right bracket 9106
1 1 Tools 9106
1 2 Removing 9106
1 3 Installing 9108
1 3 1 Preparing new part 9108
1 3 2 Welding in 9109
2 Repairing threads for securing subframe 9111
2 1 Contents of thread repair kit 9112
2 2 Repairing threads 9113
2 2 1 Drilling threads 9113
2 2 2 Cutting thread 9115
2 2 3 Inserting thread insert 9115
3 Renewing mounting bracket for subframe 9117
3 1 Tools 9118
3 2 Removing 9118
3 3 Installing 9119
3 3 1 Preparing new part 9120
3 3 2 Welding in 9121
4 Renewing front bumper carrier 9123
4 1 Tools 9124
4 2 Removing 9124
4 3 Installing 9125
4 3 1 Preparing new part 9125
4 3 2 Welding in 9126
5 Renewing upper wheel housing longitudinal member 9128
5 1 Tools 9129
5 2 Removing 9129
5 3 Installing 9130
5 3 1 Preparing new part 9131
5 3 2 Welding in 9132
6 Renewing upper inner wheel housing longitudinal member 9135
6 1 Tools 9136
6 2 Removing 9136
6 3 Installing 9138
6 3 1 Preparing new part 9138
6 3 2 Welding in 9139
7 Renewing front wheel housing 9142
7 1 Tools 9143
7 2 Removing 9143
7 3 Installing 9146
7 3 1 Preparing new part 9146
7 3 2 Welding in 9147
8 Renewing front longitudinal member 9150
8 1 Tools 9151
8 2 Removing 9151
8 3 Installing 9152
8 3 1 Preparing new part 9152
8 3 2 Welding in 9153
9 Renewing front longitudinal member (left part section) 9156
9 1 Tools 9157
9 2 Removing 9157
9 3 Installing 9159
9 3 1 Preparing new part 9160
9 3 2 Welding in 9161
9 3 3 Renewing studs 9163
10 Renewing front longitudinal member (right part section) 9165
10 1 Tools 9166
10 2 Removing 9166
10 3 Installing 9168
10 3 1 Preparing new part 9169
10 3 2 Welding in 9170
51 – Body – centre 9173
1 Renewing roof – vehicles with no panorama tilting sunroof 9173
1 1 Tools 9174
1 2 Removing 9175
1 3 Installing 9177
1 3 1 Preparing new part 9177
1 3 2 Adjusting roof depth 9178
1 3 3 Bonding roof 9179
1 3 4 Welding in 9186
2 Renewing roof – vehicles with panorama tilting sunroof 9188
2 1 Tools 9189
2 2 Removing 9189
2 3 Installing 9191
2 3 1 Preparing new part 9191
2 3 2 Adjusting roof depth 9192
2 3 3 Bonding roof 9193
2 3 4 Welding in 9200
3 Renewing A-pillar 9202
3 1 Tools 9203
3 2 Removing 9204
3 3 Installing 9205
3 3 1 Authorised parting cuts on complete side panel 9206
3 3 2 Preparing new part 9206
3 3 3 Moulded foam inserts 9207
3 3 4 Welding in 9207
4 Renewing A-pillar reinforcement (part section) 9210
4 1 Tools 9211
4 2 Removing 9211
4 3 Installing 9214
4 3 1 Preparing new part 9215
4 3 2 Moulded foam inserts 9216
4 3 3 Welding in 9216
5 Renewing upper A-pillar reinforcement (part section) 9218
5 1 Tools 9219
5 2 Removing 9220
5 3 Installing 9222
5 3 1 Preparing new parts 9223
5 3 2 Moulded foam inserts 9225
5 3 3 Welding in 9225
6 Renewing B-pillar 9231
6 1 Tools 9233
6 2 Type plate 9233
6 3 Removing 9234
6 4 Installing 9236
6 4 1 Preparing new part 9237
6 4 2 Moulded foam inserts 9238
6 4 3 Welding in 9238
7 Renewing B-pillar reinforcement 9241
7 1 Tools 9242
7 2 Type plate 9242
7 3 Removing 9243
7 4 Installing 9245
7 4 1 Preparing new part 9246
7 4 2 Moulded foam inserts 9247
7 4 3 Welding in 9247
8 Renewing B-pillar reinforcement (part section) 9249
8 1 Tools 9250
8 2 Removing 9251
8 3 Installing 9254
8 3 1 Preparing new part 9255
8 3 2 Moulded foam inserts 9257
8 3 3 Welding in 9257
9 Renewing outer side member 9261
9 1 Tools 9262
9 2 Type plate 9262
9 3 Removing 9263
9 4 Installing 9265
9 4 1 Other approved parting cuts on outer side member (sill) 9265
9 4 2 Preparing new part 9266
9 4 3 Moulded foam inserts 9267
9 4 4 Welding in 9267
10 Renewing gusset plate 9270
10 1 Tools 9270
10 2 Removing 9270
10 3 Installing 9272
10 3 1 Preparing new part 9272
10 3 2 Welding in 9273
53 – Body – rear 9275
1 Renewing rear cross panel 9275
1 1 Tools 9276
1 2 Removing 9276
1 3 Installing 9278
1 3 1 Preparing new part 9279
1 3 2 Welding in 9279
2 Renewing rear cross member 9282
2 1 Tools 9283
2 2 Removing 9283
2 3 Installing 9284
2 3 1 Preparing new part 9285
2 3 2 Welding in 9286
3 Renewing luggage compartment floor 9289
3 1 Tools 9290
3 2 Removing 9290
3 3 Installing 9292
3 3 1 Preparing new part 9292
3 3 2 Moulded foam inserts 9294
3 3 3 Welding in 9294
4 Renewing rear longitudinal member (part section) 9297
4 1 Tools 9298
4 2 Removing 9298
4 3 Installing 9300
4 3 1 Preparing new part 9300
4 3 2 Welding in 9301
5 Renewing rear longitudinal member (second parting cut – part section) 9304
5 1 Tools 9305
5 2 Removing 9305
5 3 Installing 9309
5 3 1 Preparing new part 9310
5 3 2 Moulded foam inserts 9313
5 3 3 Welding in 9313
6 Renewing side panel (part section) 9320
6 1 Removing 9322
6 2 Installing 9325
6 2 1 Authorised parting cuts on complete side panel 9325
6 2 2 Preparing new part 9325
6 2 3 Moulded foam inserts 9327
6 2 4 Welding in 9327
7 Renewing outer wheel housing liner 9331
7 1 Tools 9332
7 2 Removing 9332
7 3 Installing 9333
7 3 1 Preparing new part 9333
7 3 2 Welding in 9334

S.V 26/01/2025